Transportable single operator rig apparatus and method for optimizing drilling and/or completion

ABSTRACT

A transportable rig apparatus provides single operator control for moving pipe into and out of a wellbore. A transportable control van houses the operator. A rig carrier is utilized to transport the mast. A pipe tong is mounted in the mast and is remotely operable from the control van. Rig blocks which move up and down in the mast are remotely operable from control van. A skid mounted pipe moving member moves pipe to the mast assembly and away from the mast assembly. The pipe moving member remotely is operable from the control van. A pipe tub stores pipe and a pipe tub transfer system is operable for moving pipe from the pipe tub to the pipe moving member and for moving pipe from the pipe moving member to the pipe tub.

TECHNICAL FIELD

One possible embodiment of the present disclosure relates, generally, tothe field of producing hydrocarbons from subsurface formations. Further,one possible embodiment of the present disclosure relates, generally, tothe field of making a well ready for production or injection. Moreparticularly, one possible embodiment of the present disclosure relatesto completion systems and methods adapted for use in wells having longlateral boreholes.

BACKGROUND

In petroleum production, completion is the process of making a wellready for production or injection. This principally involves preparingthe bottom of the hole to the required specifications, running theproduction tubing and associated down hole tools, as well as perforatingand/or stimulating the well as required. Sometimes, the process ofrunning and cementing the casing is also included.

Lower completion refers to the portion of the well across the productionor injection zone, beneath the production tubing. A well designer hasmany tools and options available to design the lower completionaccording to the conditions of the reservoir. Typically, the lowercompletion is set across the production zone using a liner hangersystem, which anchors the lower completion equipment to the productioncasing string.

Upper completion refers to all components positioned above the bottom ofthe production tubing. Proper design of this “completion string” isessential to ensure the well can flow properly given the reservoirconditions and to permit any operations deemed necessary for enhancingproduction and safety.

In cased hole completions, which are performed in the majority of wells,once the completion string is in place, the final stage includes makinga flow path or connection between the wellbore and the formation. Theflow path or connection is created by running perforation guns into thecasing or liner and actuating the perforation guns to create holesthrough the casing or liner to access the formation. Modern perforationscan be made using shaped explosive charges.

Sometimes, further stimulation is necessary to achieve viableproductivity after a well is fully completed. There are a number ofstimulation techniques which can be employed at such a time.

Fracturing is a common stimulation technique that includes creating andextending fractures from the perforation tunnels deeper into theformation, thereby increasing the surface area available for formationfluids to flow into the well and avoiding damage near the wellbore. Thismay be done by injecting fluids at high pressure (hydraulic fracturing),injecting fluids laced with round granular material (proppantfracturing), or using explosives to generate a high pressure and highspeed gas flow (TNT or PETN, and propellant stimulation).

Hydraulic fracturing, often called fracking, fracing or hydrofracking,is the process of initiating and subsequently propagating a fracture ina rock layer, by means of a pressurized fluid, in order to releasepetroleum, natural gas, coal steam gas or other substances forextraction. The fracturing, known colloquially as a frack job or fracjob, is performed from a wellbore drilled into reservoir rockformations. The energy from the injection of a highly pressurized fluid,such as water, creates new channels in the rock that can increase theextraction rates and recovery of fossil fuels.

The technique of fracturing is used to increase or restore the rate atwhich fluids, such as oil or water, or natural gas can be produced fromsubterranean natural reservoirs, including unconventional reservoirssuch as shale rock or coal beds. Fracturing enables the production ofnatural gas and oil from rock formations deep below the earth's surface,generally 5,000-20,000 feet or 1,500-6,100 meters. At such depths, theremay not be sufficient porosity and permeability to allow natural gas andoil to flow from the rock into the wellbore at economic rates. Thus,creating conductive fractures in the rock is essential to extract gasfrom shale reservoirs due to the extremely low natural permeability ofshale. Fractures provide a conductive path connecting a larger area ofthe reservoir to the well, thereby increasing the area from whichnatural gas and liquids can be recovered from the targeted formation.

Pumping the fracturing fluid into the wellbore, at a rate sufficient toincrease pressure downhole, until the pressure exceeds the fracturegradient of the rock and forms a fracture. As the rock cracks, thefracture fluid continues to flow farther into the rock, extending thecrack farther. To prevent the fracture(s) from closing after theinjection process has stopped, a solid proppant, such as a sieved roundsand, can be added to the fluid. The propped fracture remainssufficiently permeable to allow the flow of formation fluids to thewell.

The location of fracturing along the length of the borehole can becontrolled by inserting composite plugs, also known as bridge plugs,above and below the region to be fractured. This allows a borehole to beprogressively fractured along the length of the bore while preventingleakage of fluid through previously fractured regions. Fluid andproppant are introduced to the working region through piping in theupper plug. This method is commonly referred to as “plug and perf.”

Typically, hydraulic fracturing is performed in cased wellbores, and thezones to be fractured are accessed by perforating the casing at thoselocations.

While hydraulic fracturing can be performed in vertical wells, today itis more often performed in horizontal wells. Horizontal drillinginvolves wellbores where the terminal borehole is completed as a“lateral” that extends parallel with the rock layer containing thesubstance to be extracted. For example, laterals extend 1,500 to 5,000feet in the Barnett Shale basin. In contrast, a vertical well onlyaccesses the thickness of the rock layer, typically 50-300 feet.Horizontal drilling also reduces surface disruptions, as fewer wells arerequired. Drilling a wellbore produces rock chips and fine rockparticles that may enter cracks and pore space at the wellbore wall,reducing the porosity and/or permeability at and near the wellbore. Theproduction of rock chips, fine rock particles and the like reduces flowinto the borehole from the surrounding rock formation, and partiallyseals off the borehole from the surrounding rock. Hydraulic fracturingcan be used to restore porosity and/or permeability.

Conventional lateral wells are completed by inserting coiled tubing or asimilar, generally flexible conduit therein, until the flexible natureof the tubing prevents further insertion. While coil tubing does notrequire making up and/or breaking out each pipe joint, coiled tubingcannot be rotated, which increases the likelihood of sticking andsignificantly reduces the ability to extend the pipe laterally. Once acertain depth is reached in a highly angled and/or horizontal well, thepipe essentially acts like soft spaghetti and can no longer be pushedinto the hole. Coiled tubing is also more limited in terms of pipe wallthickness to provide flexibility thereby limiting the weight of thestring.

Conventional completion rigs include a mast, which extends upward andslightly outward typically at approximately a 3 degree angle from acarrier or similar base structure. The angled mast provides that cablesand/or other features that support a top drive and/or other equipmentcan hang downward from the mast, directly over a wellbore, withoutcontacting the mast. For example, most top drives and/or power swivelsrequire a “torque arm” to be attached thereto, the torque arm includinga cable that is secured to the ground or another fixed structure tocounteract excess torque and/or rotation applied to the top drive/powerswivel. Additionally, a blowout preventer stack, having sufficientcomponents and a height that complies with required regulations, must bepositioned directly above the wellbore. A mast having a slight angleaccommodates for these and other features common to completion rigs. Asa result, a rig must often be positioned at least four feet, or more,away from the wellbore depending on the height of the mast. A needexists for systems and methods having a reduced footprint, especially inlucrative regions where closer spacing of wells can significantly affectproduction and economic gain, and in marginal regions, where closerspacing of wells would be necessary to enable economically viableproduction.

Prior to common use of coiled tubing, completion operations ofteninvolved the use of workover/production rigs for insertion of successivejoints of pipe, which must be threaded together and torqued, often byhand, creating a significant potential for injury or death of laborersinvolved in the completion operation, and requiring significant time toengage (e.g., “make up”) each pipe joint Drilling rigs could also beutilized to run production tubing but are more expensive although theindividual joints of pipes result in the same types of problems.

A significant problem with prior art production/workover rigs ordrilling rigs as opposed to coiled tubing units is that individualproduction tubing pipe connections are often considerably more difficultto make up and/or break out than the drilling pipe connections. Drillingpipe connections are enlarged and are designed for quick make up andbreak out many times with very little concern about exact alignment ofthe connectors. Drill pipe is designed to be frequently and quickly madeup and broken out without being damaged even if the alignment is notparticularly precise. On the other hand, production tubing is normallyintended for long term use in the well and requires much more accuratealignment of the connectors to avoid damaging the threads. Productiontubing does not typically utilize the expensive enlarged connectors likedrill pipe and, in some completions, enlarged connectors simply are notfeasible due to clearance problems within the wellbore. Thus, especiallyfor production tubing, prior art workover/production rigs are muchslower for inserting and/or removing production tubing pipe into or outof the well than coiled tubing units and are more likely to result inoperator injuries and errors during pipe connection make up and breakout than coiled tubing. There are also problems with human error inaligning the individual production tubing connectors wherebycross-threading could result in a damaged or leaking connection.

Prior art insertion techniques of completion tubing into a lateral welltherefore suffers from significant limitations including but not limitedto: 1) the longer time required to run tubing into a well; 2) operatorsafety; and 3) the maximum horizontal distance across which the tubingcan be inserted is limited by the nature of the tubing used and/or theforce able to be applied from the surface. Generally, once thefrictional forces between the lateral portion of the well and the lengthof tubing therein exceed the downward force applied by the weight of thetubing in the vertical portion of the well, further insertion becomesextremely difficult, if not impossible, thus limiting the maximum lengthof a lateral.

Due to the significant day rates and rental costs when performingoilfield operations, a need exists for systems and methods capable offaster, yet safer insertion of pipe and/or tubing into a well.Additionally, due to the costs associated with the drilling, completion,and production of a well, a need exists for systems and methods capableof extending the maximum length of a lateral, thereby increasing theproductivity of the well.

Hydraulic fracturing is commonly applied to wells drilled in lowpermeability reservoir rock. An estimated 90 percent of the natural gaswells in the United States use hydraulic fracturing to produce gas ateconomic rates.

The fluid injected into the rock is typically a slurry of water,proppants, and chemical additives. Additionally, gels, foams, and/orcompressed gases, including nitrogen, carbon dioxide and air can beinjected. Various types of proppant include silica sand, resin-coatedsand, and man-made ceramics. The type of proppant used may varydepending on the type of permeability or grain strength needed. Sandcontaining naturally radioactive minerals is sometimes used so that thefracture trace along the wellbore can be measured. Chemical additivescan be applied to tailor the injected material to the specificgeological situation, protect the well, and improve its operation,though the injected fluid is approximately 99 percent water and 1percent proppant, this composition varying slightly based on the type ofwell. The composition of injected fluid can be changed during theoperation of a well over time. Typically, acid is initially used toincrease permeability, then proppants are used with a gradual increasein size and/or density, and finally, the well is flushed with waterunder pressure. At least a portion of the injected fluid can berecovered and stored in pits or containers; the fluid can be toxic dueto the chemical additives and material washed out from the ground. Therecovered fluid is sometimes processed so that at least a portionthereof can be reused in fracking operations, released into theenvironment after treatment, and/or left in the geologic formation.

Advances in completion technology have led to the emergence of open holemulti-stage fracturing systems. These systems effectively placefractures in specific places in the wellbore, thus increasing thecumulative production in a shorter time frame.

Those of skill in the art will appreciate the present system whichaddresses the above and other problems.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate an implementation of apparatusconsistent with one possible embodiment of the present disclosure and,together with the detailed description, serve to explain advantages andprinciples consistent with the disclosure. In the drawings,

FIG. 1 illustrates an embodiment of a long lateral completion systemusable within the scope of one possible embodiment of the presentdisclosure.

FIG. 2 is a perspective view of the mast assembly, pipe arm, pipe tubs,and the carrier of the long lateral completion system of FIG. 1 inaccord with one possible embodiment of the completion system of thepresent disclosure.

FIG. 3 is a plan view of the carrier, mast assembly, pipe arm, and pipetub of the long lateral completion system of FIG. 1 in accord with onepossible embodiment of the completion system of the present disclosure.

FIG. 4 is an illustration of the carrier of the long lateral completionsystem of FIG. 1 in accord with one possible embodiment of thecompletion system of the present disclosure.

FIG. 4A-A is a cross sectional view of the carrier of FIG. 4 taken alongthe section line A-A in accord with one possible embodiment of thecompletion system of the present disclosure.

FIG. 4B-B is a cross sectional view of the carrier of FIG. 4 taken alongthe section line B-B in accord with one possible embodiment of thecompletion system of the present disclosure.

FIG. 5 is an elevation view of the carrier, the mast assembly, the pipearm and the pipe tubs of the long lateral completion system of FIG. 1 inaccord with one possible embodiment of the completion system of thepresent disclosure.

FIG. 5A is an enlarged or detailed view of the section identified inFIG. 5 as “A” of the rear portion of the carrier engaged with a skid ofthe depicted long lateral completion system in accord with one possibleembodiment of the completion system of the present disclosure.

FIG. 6 illustrates an elevation view of the completion system of FIG. 1with the mast assembly extended in a perpendicular relationship with thecarrier and the pipe tubs in accord with one possible embodiment of thecompletion system of the present disclosure.

FIG. 6A is an enlarged or detailed view of the portion of FIG. 6indicated as section “A” illustrating the relationship of the mastassembly, the deck and the base beam in accord with one possibleembodiment of the completion system of the present disclosure.

FIG. 7 is an elevation view of the carrier, the mast assembly, the pipearm, and the pipe tub of FIG. 1, with the mast assembly shown in aperpendicular relationship with the carrier, and the pipe arm engagedwith the mast in accord with one possible embodiment of the completionsystem of the present disclosure.

FIG. 7A-A is a cross sectional view of FIG. 7 taken along the sectionline A-A showing the mast assembly and top drive of the depicted longlateral completion system in accord with one possible embodiment of thecompletion system of the present disclosure.

FIG. 7B is a perspective view of the portion of the mast assembly andpipe arm illustrated in FIG. 7A-A in accord with one possible embodimentof the completion system of the present disclosure.

FIG. 8 is an elevation view of the completion system of FIG. 1illustrating the mast assembly in a perpendicular relationship with thecarrier, including the use of a hydraulic pipe tong in accord with onepossible embodiment of the completion system of the present disclosure.

FIG. 8A-A is a cross sectional view of the system of FIG. 8 taken alongthe section line A-A, showing the pipe tong with respect to the mastassembly in accord with one possible embodiment of the completion systemof the present disclosure.

FIG. 8B-B is a cross sectional view of the system of FIG. 8 taken alongthe section line B-B, showing the mast assembly and top drive in accordwith one possible embodiment of the completion system of the presentdisclosure.

FIG. 8C is a perspective view of the portion of the system shown in FIG.8B in accord with one possible embodiment of the completion system ofthe present disclosure.

FIG. 9 is an illustration of the long lateral completion system of FIG.1, depicting the relationship between the carrier, the mast assembly,the pipe arm, the pipe tubs and a blowout preventer in accord with onepossible embodiment of the completion system of the present disclosure.

FIG. 9A-A is a cross sectional view of the system of FIG. 9 taken alongthe section line A-A, illustrating the upper portion of the mastassembly in accord with one possible embodiment of the completion systemof the present disclosure.

FIG. 9B-B is a perspective view of the upper portion of the mastassembly as illustrated in FIG. 9A-A, showing the top drive and the pipeclamp in accord with one possible embodiment of the completion system ofthe present disclosure.

FIG. 9C-C is a cross sectional view of the system of FIG. 9 taken alongthe section line C-C, illustrating the relationship of the blowoutpreventer to the completion system in accord with one possibleembodiment of the completion system of the present disclosure.

FIG. 10A is an illustration of an embodiment of a pipe tong fixtureusable in accord with one possible embodiment of the completion systemof the present disclosure.

FIG. 10B is a perspective view of the pipe tong fixture of FIG. 10A.

FIG. 11A, FIG. 11B, FIG. 11C, and FIG. 11D illustrate an embodiment of acompact snubbing unit usable in accord with one possible embodiment ofthe completion system of the present disclosure.

FIG. 12A is a schematic view of an embodiment of a control cabin usablein accord with one possible embodiment of the completion system of thepresent disclosure.

FIG. 12B is an elevation view of the control cabin of FIG. 12A in accordwith one possible embodiment of the completion system of the presentdisclosure.

FIG. 12C is a first end view (e.g., a left side view) of the controlcabin of FIG. 12A in accord with one possible embodiment of thecompletion system of the present disclosure.

FIG. 12D is an opposing end view (e.g., a right side view) of thecontrol cabin of FIG. 12A in accord with one possible embodiment of thecompletion system of the present disclosure.

FIG. 13 is an illustration of an embodiment of a carrier adapted for usein accord with one possible embodiment of the completion system of thepresent disclosure.

FIG. 14 is an illustration of an embodiment of a pipe arm usable inaccord with one possible embodiment of the completion system of thepresent disclosure.

FIG. 14A depicts a detail view of an engagement between the pipe arm ofFIG. 14 and an associated skid in accord with one possible embodiment ofthe completion system of the present disclosure.

FIG. 15A is an elevation view of the pipe arm of FIG. 14 in accord withone possible embodiment of the completion system of the presentdisclosure.

FIG. 15B is an exploded view of a portion of the pipe arm of FIG. 15A,indicated as section “B” in accord with one possible embodiment of thecompletion system of the present disclosure.

FIG. 15C is an enlarged or detailed view of a portion of the pipe arm ofFIG. 15A, indicated as section “C” in accord with one possibleembodiment of the completion system of the present disclosure.

FIG. 15D is an enlarged or detailed view of a portion of the pipe arm ofFIG. 15A, indicated as section “D” in accord with one possibleembodiment of the completion system of the present disclosure.

FIG. 15E is a plan view of the pipe arm of FIG. 14 in accord with onepossible embodiment of the completion system of the present disclosure.

FIGS. 15F and 15G are end views of the pipe arm of FIG. 14 in accordwith one possible embodiment of the completion system of the presentdisclosure.

FIG. 16A is an elevation view of the pipe arm of FIG. 14 in accord withone possible embodiment of the completion system of the presentdisclosure.

FIG. 16B is a plan view of the pipe arm of FIG. 14 in accord with onepossible embodiment of the completion system of the present disclosure.

FIG. 16C is an enlarged or detailed view of a portion of the pipe arm ofFIG. 16 A, indicated as section “C” in accord with one possibleembodiment of the completion system of the present disclosure.

FIG. 16D is an end view of the pipe arm of FIG. 14 in accord with onepossible embodiment of the completion system of the present disclosure.

FIG. 17 is a perspective view of an embodiment of a kickout arm usablein accord with one possible embodiment of the completion system of thepresent disclosure.

FIG. 17A is an enlarged or detailed view of an embodiment of a clamp ofthe kickout arm of FIG. 17 in accord with one possible embodiment of thecompletion system of the present disclosure.

FIG. 18A is an elevation view of the kickout arm of FIG. 17 in accordwith one possible embodiment of the completion system of the presentdisclosure.

FIG. 18B is a bottom view of the kickout arm of FIG. 17 in accord withone possible embodiment of the completion system of the presentdisclosure.

FIG. 18C is a top view of the kickout arm of FIG. 17 in accord with onepossible embodiment of the completion system of the present disclosure.

FIG. 18B-B is a sectional view of the end taken along the section lineB-B in FIG. 18B in accord with one possible embodiment of the completionsystem of the present disclosure.

FIG. 18C-C is a cross sectional view of the kickout arm of FIG. 18Ctaken along the section line C-C in accord with one possible embodimentof the completion system of the present disclosure.

FIG. 19A is an elevation view of an embodiment of a top drive fixtureusable with the mast assembly of embodiments of the completion system inaccord with one possible embodiment of the completion system of thepresent disclosure.

FIG. 19B is a side view of the top drive fixture illustrated in FIG. 19Ain accord with one possible embodiment of the completion system of thepresent invention.

FIG. 19C-C is a cross sectional view of the top drive fixture of FIG.19B taken along the section line C-C in accord with one possibleembodiment of the completion system of the present disclosure.

FIG. 19D is an enlarged or detailed view of a portion of the top drivefixture of FIG. 19B indicated as section “D” in accord with one possibleembodiment of the completion system of the present disclosure.

FIG. 19E-E is a cross sectional view of the top drive fixture of FIG.19A taken along the section line E-E in accord with one possibleembodiment of the completion system of the present disclosure.

FIG. 20A is an illustration of a top drive within the top drive fixtureof FIG. 19A in accord with one possible embodiment of the completionsystem of the present disclosure.

FIG. 20 A-A is a cross sectional view of the top drive and fixture ofFIG. 20A taken along section line A-A in accord with one possibleembodiment of the completion system of the present disclosure.

FIG. 20B is a top view of the top drive and fixture of FIG. 20A inaccord with one possible embodiment of the completion system of thepresent disclosure.

FIG. 21A is a perspective view of a pivotal pipe arm having a pipethereon with pipe clamps retracted to allow a pipe to be received intoreceptacles of the pipe arm in accord with one possible embodiment ofthe completion system of the present disclosure.

FIG. 21B is a perspective view of a pivotal pipe arm having a pipethereon with pipe clamps engaged with the pipe whereby the pipe arm canbe moved to an upright position in accord with one possible embodimentof the completion system of the present disclosure.

FIG. 22A is an end perspective view of a walkway with pipe movingelements whereby the pipe moving elements are positioned to urge pipeinto a pipe arm in accord with one possible embodiment of the completionsystem of the present disclosure.

FIG. 22B is an end perspective view of a walkway with pipe movingelements whereby a pipe has been urged into a pipe arm by pipe movingelements in accord with one possible embodiment of the completion systemof the present disclosure.

FIG. 23A is an end perspective view of a pipe feeding mechanism wherebya pipe is transferred from a pipe tub into a pipe arm in accord with onepossible embodiment of the present disclosure.

FIG. 23B is another end perspective view of a pipe feeding mechanismwhereby a pipe is transferred from a pipe tub into a pipe arm in accordwith one possible embodiment of the present disclosure.

FIG. 23C is a cross sectional view of a pipe feeding mechanism whereby apipe is transferred from a pipe tub into a pipe arm in accord with onepossible embodiment of the present disclosure.

FIG. 23D is a cross sectional view of a pipe feeding mechanism with thepipes removed in accord with one possible embodiment of the presentdisclosure.

FIG. 23E is a cross sectional view of a pipe feeding mechanism whereby apipe is transferred from a pipe tub into a pipe arm in accord with onepossible embodiment of the present disclosure.

FIG. 24A is a perspective view of an embodiment of a gripping apparatusengageable with a top drive of one possible embodiment of the presentdisclosure.

FIG. 24B depicts a diagrammatic side view of the gripping apparatus ofFIG. 24A.

FIG. 25A is an exploded perspective view of a guide apparatus engageablewith a top drive in accord with one possible embodiment of the presentdisclosure.

FIG. 25B is a diagrammatic side view of the guide apparatus of FIG. 25A.

FIG. 26 is a top view of a roller engaged with a guide rail in accordwith one possible embodiment of the present disclosure.

FIG. 27A is a top view of a crown block sheave assembly showing an axisof rotation in accord with one possible embodiment of the presentdisclosure.

FIG. 27B is a top view of a traveling sheave block showing an axis ofrotation in accord with one possible embodiment of the presentdisclosure.

FIG. 28A is a perspective view of a system for conducting a long lateralwell completion system of multiple wellheads in close proximity inaccord with one possible embodiment of the present invention.

FIG. 28B is another perspective view of a system for conducting a longlateral well completion system of multiple wellheads in close proximityin accord with one possible embodiment of the present invention.

The above general description and the following detailed description aremerely illustrative of the generic invention, and additional modes,advantages, and particulars of this invention will be readily suggestedto those skilled in the art without departing from the spirit and scopeof the invention.

DESCRIPTION OF EMBODIMENTS

FIG. 1 illustrates an embodiment of a long lateral completion system 10usable in accord with one possible embodiment of the completion systemof the present disclosure. In this embodiment, the completion system 10is shown having a mast assembly 100, which extends in a generallyvertical direction (i.e., perpendicular to the rig carrier 600 and/orthe earth's surface), a pipe handling mechanism 200, a catwalk-pipe armassembly 300, two pipe tubs 400, a pump pit combination skid 500, a rigcarrier 600 usable to transport the mast assembly 100 and varioushydraulic and/or motorized pumps and power sources for raising andlowering the mast assembly 100 and operating other rig components, and acontrol van 700, used to control operation of one or more of thecomponents of long lateral completion system 10. Other embodiments maycomprise the desired completion system 10 components otherwise arrangedon skids as desired. For example, in another embodiment, separate pumpand pit skids might be utilized. In another embodiment, catwalk pipetubes with tube handling elements might be combined on one skid withpipe arm assembly 300 provided separately. It will be appreciated thatmany different embodiments may be utilized. Accordingly, FIG. 1 showsone possible arrangement of various components of the completion system10 that can be implemented around a well (e.g., an oil, natural gas, orwater well). Due to the construction, system 10 can work with wells thatare in close proximity to each other, e.g. within ten feet of eachother. For example, mast assembly 100 may be located above a first well,as discussed hereinafter, and rig floor 102 (if used) may be elevatedabove a second capped wellhead (not shown) within ten feet of the firstwell. Sensors, such as laser sights, guides mounted to the rear of rigcarrier 600, and the like may be utilized, e.g., mounted to and/orguided to the well head, to locate and orient the axis of drilling rigmast 100 precisely with respect to the wellbore, which in one embodimentmay be utilized to align a top drive mounted on guide rails with thewellbore, as discussed hereinafter.

Control van 700 and automated features of system 10 can allow a singleoperator in the van to view and operate the truck mounted production rigby himself, including raising the derrick, picking up pipe, torqueing tothe desired torque levels for tubing, going in the hole, coming out ofthe hole, performing workover functions, drilling out plugs, and/orother steps completing the well, which in the prior art required a rigcrew, some problems of which were discussed above. In other embodiments,the control van 700 and/or other features can be configured for use andoperation by multiple operators. Control van 700 may comprise a windowarrangement with windows at the top, front, sides and rear (See e.g.,FIG. 12B), so that once positioned in a desired position on the wellsite, all operations to the top of mast 100 are readily visible.

For example, embodiments of the system 10 can be positioned for realtime operation, e.g., by a single individual operating the control van700 and/or a similar control system, and further embodiments can be usedto perform various functions automatically, e.g., after calibrating thesystem 10 for certain movements of the pipe arm assembly 300, the topdrive or a similar type of drive unit along the mast assembly 100, etc.After providing the system 10 in association with a wellbore, e.g., byerecting the mast assembly 100 vertically thereabove, a tubular segmentcan be transferred from one or more pipe tubs and/or similar vessels tothe pipe arm assembly 300, and the control van 700 and/or a similarsystem can be used to engage the tubular segment with a pipe moving armthereof. For example, as described hereinafter, hydraulic members of thepipe tubs and/or similar vessels can be used to urge a tubular memberover a stop into a position for engagement with a pipe moving arm, whilehydraulic grippers thereof can be actuated to grip the tubular member.The control system can then be used to raise the pipe moving arm andalign the tubular segment with the mast assembly, which can includeextension of a kick-out arm from the pipe moving arm, further describedbelow. Alignment of the tubular segment with the mast assembly couldfurther include engagement of the tubular segment by grippers (e.g.,hydraulic clamps and/or jaws) positioned along the mast. The controlsystem is further usable to move the top drive along the mast assemblyto engage the tubular segment (e.g., through rotation thereof), todisengage the pipe moving arm from the tubular, and to further move thetop drive to engage the tubular segment with a tubular string associatedwith the wellbore. While the system is depicted having a pipe moving armused to raise gripped segments of pipe into association and/or alignmentwith the mast, in other embodiments, a catwalk-type pipe handling systemin which the front end of each pipe segment is pulled and/or lifted intoa desired position, while the remainder of the pipe segment travelsalong a catwalk, can be used.

In an embodiment, any of the aforementioned operations can be automated.For example, the control system can be used to calibrate movement of thedrive unit along the mast assembly, e.g., by determining a suitablevertical distance to travel to engage a top drive with a tubular segmentpositioned by the pipe moving arm, and a suitable vertical distance totravel to engage a tubular segment engaged by the top drive with atubular string below, such that movement of a top drive betweenpositions for engagement with tubular members and engagement of tubularmembers with a tubular string can be performed automatically thereafter.The control system can also be used to calibrate movement of the pipemoving arm between raised and lowered positions, depending on theposition of the mast assembly 100 relative to the pipe arm assembly 300after positioning the system 10 relative to the wellbore. Then, futuremovements of the pipe moving arm, and the kick-out arm, if used, can beautomated. In a similar manner, grippers on the mast assembly 100, ifused, annular blowout preventers and/or ram/snubbing assemblies, andother components of the system 10 can be operated using the controlsystem, and in an embodiment, in an automated fashion. After assembly ofa completion string, further operations, such as fracturing, production,and/or other operations that include injection of substances into orremoval of substances from the wellbore can be controlled using thecontrol system, and in an embodiment, can be automated. In embodimentswhere a catwalk-type pipe handling system is used, operations of thecatwalk-type pipe handling system can also be highly automated,including engagement of the front end of a pipe segment, lifting and/orotherwise moving the front end of the pipe segment, and the like.

FIG. 2 is a perspective view of the mast assembly 100, catwalk-pipe armassembly 300, pipe tubs 400, and the carrier 600 of the long lateralcompletion system 10 in accord with one possible embodiment of thecompletion system of the present invention. The carrier 600 has the mastassembly 100 extending from the rear portion of the carrier 600. In oneembodiment, the mast assembly 100 is essentially perpendicular to thecarrier 600. In another embodiment, mast assembly 100 is aligned eithercoaxially, within less than three inches, or two inches, or one inch toan axis of the bore through the wellhead, BOPs, or the like when the topdrive is positioned at a lower portion of the mast and/or is parallel tothe axis of the borehole adjacent the surface of the well and/or thebore of the wellhead pressure equipment within less than five degrees,or less than three degrees, or less than one degree in anotherembodiment. For example, in one embodiment, mast rails 104, which guidetop drive 150, may be aligned to be essentially parallel to the axis ofthe bore, within less than five degrees in one embodiment, or less thanthree degrees, or less than one degree in another embodiment, wherebytop drive 150 moves coaxially or concentric to the well bore within adesired tolerance. As used herein a well completion system may beessentially synonymous with a workover system or drilling system or rigor drilling rig or the like. The system of the present invention may beutilized for completions, workovers, drilling, general operations, andthe like and the term workover rig, completing rig, drilling rig,completion system, intervention system, operating system, and the likeare used herein substantially interchangeably for the herein describedsystem. Pipe as used herein may refer interchangeably to a pipe string,a single pipe, a single pipe that is connected to or removed from a pipestring, a stand of pipe for connection or removal from a pipe string, ora pipe utilized to build a pipe string, tubular, tubulars, tubularstring, oil country tubulars, or the like.

The carrier 600 is illustrated with a power plant 650 and a winch ordrawworks assembly 620. Winch or drawworks 620 can be utilized forlifting and lowering the top drive 150 in mast 100 utilizing pulleyarrangements in crown 190 and blocks associated with top drive 150. Themast positioning hydraulic actuators 630 provide for lifting the mastassembly 100 into a desired essentially vertical position, with respectto the axis of the borehole at the surface of the well, within a desiredaccuracy alignment angle. In one embodiment, a laser sight may bemounted to the wellbore with a target positioned at an upper portion ofthe mast to provide the desired accuracy of alignment. In thisembodiment, crown laser alignment target 192 is provided adjacent crown190. The mast assembly 100 is affixed to the rear portion of the carrier600. Also the mast assembly 100 is illustrated with a top drive 150 anda crown 190. The top drive allows rotation of the tubing, which resultsin significant improvement when inserting pipe into high angled and/orhorizontal well portions. Further associated with the mast assembly 100and the carrier 600 is a mast support base beam 120 for providingstability to the carrier 600 and the mast assembly 100, e.g., byincreasing the surface area that contacts the ground.

In one possible embodiment, a catwalk-pipe arm assembly 300 may belocated proximate to the mast assembly 100, which, in one possibleembodiment, may be utilized to automatically insert and/or remove pipefrom the wellbore. In one embodiment, the pipe is not stacked in the rigbut instead is stored in one or more moveable pipe tubs 400.Catwalk-pipe arm assembly 300 may be configured so that components areprovided in different skids, as discussed hereinbefore, and as discussedhereinafter to some extent. In this example, catwalk-pipe arm assembly300 has associated on either side thereof a pipe tub 400. However, pipetubes 400 may be used on only one side, two on one side, or anyconfiguration may be utilized that fits with the well site. While morethan two pipe tubes can be utilized, usually not more than four pipetubs are utilized. However, pipe racks or other means to hold and/orfeed pipe may be utilized. It can be appreciated that multiple pipe tubs400 are provided for supplying multiple pipes to the catwalk-pipe armassembly 300. Pipe tubs 400 may or may not comprise feed elements, whichguide each pipe as needed to roll across catwalk 302 to pivotal pipe arm320. Conceivably, means (not shown) may be provided which allowtorqueing two or more pipes from associated pipe tubes forsimultaneously handling stands of pipes utilizing pivotal pipe arm 300for faster insertion into the well bore. However, in the presently shownembodiment, only one pipe at a time is typically handled by pipe arm300. When handling stands of pipe, then the correspondingly lengthenedmast 100 may be carried in multiple carrier trucks 600.

The pipe tubs are preferably capable of holding multiple joints of pipefor delivery to the pipe arm. The pipe tubs are further preferablycapable of continuously lifting and feeding a section of pipe to thepipe arm. The pipe tubs in some embodiments can be positioned in anorientation substantially parallel to the pipe arm, so that the sectionsof pipe are in a length-wise orientation parallel to the pipe arm. Apipe tub may further comprise a hydraulic lifting system for raising thefloor or bottom shelf of the pipe tub in an upwards direction away fromthe ground and additionally may be used to tilt the pipe tub, so as tolift and roll one or more sections of pipe into a position to bereceived by the pipe arm. The pipe tubs could additionally include aseries of pins along the edge of the pipe tub closest to the pipe arm,which feeds the sections of pipe to the pipe arm. However, preferablythe series of pins are disposed on the pipe arm skid at a locationproximate to the adjacent edge of the pipe tubs. These pins serve thepurpose of stopping or preventing a joint of pipe from rolling onto thepipe arm or pipe arm skid prematurely. Each pipe tub used in the pipehandling system can further incorporate one or more flipper arms, whichare hydraulically actuated arms or plates to push or bump a section ofpipe over the above mentioned pins when the pipe handling skid and pipearm are in a position to receive the said section of pipe. Preferably,the pipe arm skid includes one or more flipper arms which pivotallyrotate in an upward direction and which engage the joints of pipe tolift the joints of pipe over the pins retaining the joint(s) of pipe,whether the pins are disposed along the edge of the pipe arm skid or onthe edge of the pipe tub. It can be appreciated that as an alternativeto the pipe tubs 400, pipe ramps, saw horses, or tables can be used. Theselection of the apparatus (e.g. pipe tubs, ramps, saw horses, ortables) for delivery of pipe joints to the pipe arm depends on thephysical layout of the surrounding area and if there are anyobstructions or hazards that need to be avoided or overcome.

Various types of scanners such as laser scanners for bar codes, RFIDs,and the like may be utilized to monitor each pipe whereby the amount ofusage, the length, torque history and other applied stresses, testinghistory of wall thickness, wear, and the like may be recorded,retrieved, and viewed. If desired, the pipe tub and/or catwalk maycomprise sensors to automatically measure the length of each pipe. Thus,the operator in the van can automatically keep a pipe tally to determineaccurate depths/lengths of the pipe string in the well bore. Torquesensors may be utilized and recorded so that the torque record showsthat each connection was accurately aligned and properly torqued, and/orimmediately detect/warn of any incorrectly made up connection.

FIG. 3 is a plan view of one possible embodiment of carrier 600, mastassembly 100, catwalk-pipe arm assembly 300 and pipe tub 400 of the longlateral completion system 10 pursuant to one possible embodiment of thepresent invention The carrier 600 is illustrated with the power plant650 and the winch or drawworks assembly 620 The mast assembly 100 isdisposed at a rear extremity of the carrier 600 and adjacent to thewinch or drawworks assembly 620 In this embodiment, base beam 120 isdisposed beneath and/or adjacent to the mast assembly 100 for providingsecurity/stability for the mast assembly 100 Base beam 120 may comprisewide flat mats 122, (also shown in FIG. a which are pushed downwardly bybase beam hydraulic actuators 612 (shown in FIG. 2 and better shown inFIG. 8A-A). In one possible embodiment, wide flat mats 122 may be 50percent to 200 percent as wide as mast 100 Wide flat mats 122 may foldupon each other and/or extend telescopingly or slidingly outwardly fromcarrier 600 and/or hydraulically Wide flat mats 122 may be slidinglysupported on beam runner 124 and may be transported on carrier 600 orprovided separately with other trucks

In this embodiment, catwalk-pipe arm assembly 300 is affixed to mastassembly 100 and carrier 600 by rig to arm connectors 305 (also shown inFIG. 2) In this embodiment, catwalk-pipe arm assembly 300 is shown witha pipe tub 400 on both sides of the catwalk-pipe arm assembly 300 Thepipe tubs 400 are shown with the side supports 402, the end support 404and a cavity 420 A plurality of pipes (not illustrated) is placed in thepipe tubs 400 Pipes are displaced on to the catwalk-pipe arm assembly300 and lifted up to the mast assembly 100. Catwalk 302 may be somewhatV-shaped or channeled to urge pipes to roll into the center for receiptand clamping, utilizing catwalk—pipe arm assembly 300 Catwalk 302provides a walkway surface for workers and the like Additional pipe tubs400 can be slid into place to provide for a continuum of pipe lengthsfor use by the completion system 10 Acoustic and/or laser and/or sensorsor RFID transceivers 408 and 410 may be positioned on ends 404 and sides402 of pipe tubs 400, or elsewhere as desired, to measure and/or detectthe lengths of the pipes, and to detect RFIDs, bar codes, and/or otherindicators which may be mounted to the pipes Alternatively, pipe lengthsensors 412, 414 may each comprise one or more sensors, which may bemounted to pipe arm 320. In one embodiment, sensors 412, 414 maycomprise acoustic, electromagnetic, or light sensors which may beutilized to detect features such as length of the pipe. Pipe connectioncleaning/grease injectors 416, 418 may be provided for wire brushing,grease injecting, thread protector removal and other automatedfunctions, if desired.

In one embodiment, sensors 412, 414 may comprise thread protectorsensors provided to ensure that the thread protectors have been removedfrom both ends of a pipe. Thread protectors are generally plastic orsteel and used during transportation to prevent any damage to thethreading of pipe. Damage as a result of faulty or damaged threads couldjeopardize a well site and the safety of the workers therein. However,failing to remove a thread protector can cause the same potentialdangers if not found before inserted into the pipe string. The pipe willnot mate properly with the threads of the pipe string, comprising theintegrity of the entire pipe string and well site. The thread protectorsensors 412, 414 may be acoustic sensors or lasers used to determinewhether the thread protectors have been removed and communicate thisdata with the control system. If the thread protectors are present, anacoustic or light signal transmitted by sensor 412 may be reflectedrather than received at sensor 414. Alternatively, sensors 412 and 414may be transceivers that will not receive a signal unless the threadprotector is present. In another embodiment, a light detector willdetect a different profile. In another embodiment, sensors 412 and 414may comprise a camera in addition to other thread protector sensors. Ifthe thread protectors have not been removed, an operator will beinformed before attempting to make up the pipe connection so that theproblem can be fixed.

In one possible embodiment, inner portion adjacent catwalk 302 and/orcatwalk edges 301 and 307 may comprise gated feed compartments wherebypipes are fed into a compartment or funnel large enough for only singlepipes or stands of pipes, and then gated to allow individual pipes orstands of pipes to be automatically rolled onto either side of catwalk302.

FIG. 4 is an illustration of the carrier 600 of the long lateralcompletion system 10 in accord with one possible embodiment of thecompletion system of the present disclosure. The carrier 600 isillustrated with the power plant 650 and the winch or drawworks assembly620. Also, the mast assembly 100 is illustrated in a lowered orhorizontal position, which is essentially parallel relationship with thecarrier 600. Mast 100 is clamped into the generally horizontal positionwith carrier front clamp/support 633 above cab 605. Mast 100 is hingedat mast to carrier pivot 634 so that the mast is secured from anyforward/reverse/side-to-side movement with respect to carrier 600 duringtransport after being clamped at the front and/or elsewhere. In thisembodiment, mast positioning hydraulic actuators 630 are pivotallymounted with respect to carrier walkway 602 so that when extended, thehydraulic actuators 630 are angled toward the rear instead of toward thefront of carrier 600 as in FIG. 4 (See for example FIG. 2). In oneembodiment, mast positioning hydraulic actuators 630 may comprisemultiple telescopingly connected sections as shown in FIG. 6A. Thehorizontally disposed mast assembly 100 is illustrated for moving on thehighway and for arrangement in the proximate location with respect to awellbore. It will be noted that hydraulic pipe tongs 170 are mounted tomast 100 so that when the mast 100 is lowered pipe tongs 170 are in aposition generally perpendicular to the operational position. Movementsand actuation of the pipe tongs can be fully automated, for formingand/or breaking both shoulder connections and collared connections. Themast assembly 100 has the crown 690 extending in front of the carrier600. In one embodiment, rig carrier is less than 20 feet high, or lessthan 15 feet high, while still allowing the rig to work with well headequipment having a height of about 20 feet. This is due to theconstruction of the mast with the Y-frame connection as discussedherein. The rig floor can be adjusted to a convenient height and is notnecessarily fixed in height. In an embodiment, the rig floor could beconnected to snubbing jacks.

FIG. 4A-A is a top view taken along the line A-A in FIG. 4 of the mastassembly 100 of the long lateral completion system pursuant to onepossible embodiment of the present invention. FIG. 4A-A illustrates adownward view of the mast assembly 100. The mast assembly 100 shows thetop drive assembly or fixture 150 (also shown in FIG. 4) affixed to theportion of the mast assembly 100 over the winch or drawworks assembly620 over the carrier 600. The top drive assembly or fixture 150 isprovided at the location associated with the carrier 600 fordistributing the load associated with the carrier 600 for easytransportation on the highway. Top drive or fixture 150 may be clampedor pinned into position with clamps or pins 162 or the like that areinserted into holes within mast 100 at the desired axial position alongthe length of mast 100. Angled struts 134 (also shown in FIG. 4) onY-section 132, which may be utilized in one possible embodiment of mast100, are illustrated in the plan view. Top drive 150 is shown with end163, which may comprise a threaded connector and/or tubular guide memberand/or pipe clamping elements and/or torque sensors and/or alignmentsensors.

FIG. 4B-B is an end elevational view taken along the line B-B in FIG. 4of the carrier 600 and the mast assembly 100 of the long lateralcompletion system 10 of in accord with one possible embodiment of thecompletion system of the present disclosure. FIG. 4B-B illustrates thecarrier 600, the winch or drawworks assembly 620 and the top drive 150.In this view, vertical top drive guide rails 104 are shown, upon whichtop drive 150 is guided, as discussed hereinafter. In this embodiment,it will also be noted that top drive threaded connector and/or guidemember and/or clamp portion 163 is positioned in the plane definedbetween vertical top drive guide rails 104. In this embodiment, the viewalso shows one or more angled struts 134, which may comprise Y section132 of one possible embodiment of mast 100, which is discussed in moredetail with respect to FIG. 6A.

FIG. 5 is an elevation view of the carrier 600, the mast assembly 100,and the catwalk-pipe arm assembly 300 of the long lateral completionsystem 10 with respect to one possible embodiment of the presentinvention. The carrier 600 is illustrated with the power plant 650 andthe winch or drawworks assembly 620. The cable from drawworks 620 tocrown 190 is not shown but may remain connected during transportationand raising of mast 100. The drawworks cable may be pulled fromdrawworks 620 as mast 100 is raised. The mast assembly is illustratedengaged at the rear extremity of the carrier 600. The mast assembly 100is in a vertical arrangement such that it is at an essentiallyperpendicular relationship with the carrier 600. The mast assembly 100is illustrated with the top drive 150 in an upper position near thecrown 190. The pivotal pipe arm 320 is shown in an angled dispositionslightly above catwalk 302 for clarity of view. Pivotal pipe arm 320 isshown with pipe 321 clamped thereto. The catwalk-pipe arm assembly 300is engaged or connected via rig to arm assembly connectors 305 with thecarrier 600 and the mast assembly 100. Rig to arm assembly connectors305 provide that the spacing arrangement between pivotal pipe arm 320and mast 100 and/or carrier 600 is affixed so the spacing does notchange during operation. Rig to arm assembly connectors 305 may comprisehydraulic operators for precise positioning of the spacing between mast100 and pivotal pipe arm 320, if desired.

FIG. 5A is an enlarged or detailed view of a section shown in FIG. 5 asthe rear portion of the carrier 600 engaged with a skid or mast supportbase beam 120 of the long lateral completion system 10 with respect toone possible embodiment of the present invention. Mast positioninghydraulic actuators 630 are provided for lowering and raising the mastassembly 100 with respect to the carrier 600, about mast to carrierpivot connection 634. Brace 632 for Y-base or support section 130provides additional support for mast 100.

FIG. 6 illustrates the completion system 10 in a side elevational viewwith the mast assembly 100 extended in a perpendicular relationship withthe carrier 600 and the pipe tubs 400 of the long lateral completionsystem 10 with respect to one possible embodiment of the presentinvention. The pivotal pipe arm 320 is angularly disposed with respectto the catwalk 302. The mast assembly 100 is illustrated with the topdrive 150 slightly below the crown 190. Alternately, and not required inpracticing the present disclosure, guy wires 101 can be engaged betweenthe crown 190 of the mast assembly 100 and the carrier 600 on oneextreme and the remote portion of a pipe tube 400 on the other extreme.However, one or more guy wires could be anchored to the ground and/ormay not be utilized. One or more guy wires can also be secured to theends of base beam 120. It can be appreciated that the rigidity of themast assembly 100 with respect to the carrier 600 and the base beam 120does not require guy wires 101. However, it may be appropriate in aparticular situation or in severe weather conditions to adapt thepresent disclosure for use with such guy wires 101. The carrier isillustrated with the power plant 650 and the winch or drawworks assembly620 on the carrier deck 602.

FIG. 6A is an enlarged or detailed view of the portion of FIG. 6illustrating the relationship of the mast assembly 100, the deck 602 andthe base beam 120 of the long lateral completion system 10 with respectto one possible embodiment of the present invention. FIG. 6A shows therelationship of the mast assembly 100, the deck 602 of the carrier 600and the base beam 120. It will be noted that base beam widening sections121 may extend or slide outwardly from base beam 120 and be pinned intoposition with pin 123. Also illustrated is what may comprise multiplesegments of mast positioning hydraulic actuators 630 for angularlydisposing the mast assembly 100 in a proximately perpendicularrelationship with the carrier 600, and aligned with respect to the wellbore, as discussed hereinbefore. Above the deck 602 of the carrier andaffixed with the mast assembly 100 is a hydraulic pipe tong 170. Thehydraulic pipe tong 170 is usable for handling the pipe as it is placedinto a well, e.g., by receiving joints of pipe from the pipe arm and/orthe top drive. The lower extremity of the mast assembly 100 includes ay-base 130, which defines a recessed region above the wellbore at thebase of the mast assembly 100, for accommodating a blowout preventerstack, snubbing equipment, and/or other wellhead components. Therecessed region enables the generally vertical mast assembly 100 to bepositioned directly over a wellbore without causing undesirable contactbetween blowout preventers and/or other wellhead components and the mastassembly 100.

The lower extremity of the mast assembly 100 is defined by the y-base130. The y-base 130 provides a disposed arrangement for making andinserting pipe using the completion system 10 in accord with onepossible embodiment of the completion system of the present invention.Y-base 130 supports Y section 132, which extends angularly with angledstrut 134 out to support one side of mast 100. This constructionprovides an opening or space 136 for the BOP assembly, such as BOP (seeFIG. 9), snubbing unit (see FIG. 11A), Christmas tree, well head, and/orother pressure control equipment. Mast 100 is supported by carrier tomast pivot connection 634 and at the carrier 600 rearmost position bymast support plate 636 (also shown in FIG. 4). Mast support plate 636may be shimmed, if desired. In another embodiment, mast support platemay be mounted to be slightly moveable upwardly or downwardly withhydraulic controls to support the desired angle of mast 100, which asdiscussed above may be oriented to a desired angle (e.g. less than fivedegrees or in another embodiment less than one degree) with respect tothe axis of the bore of the well bore and/or bore of BOP 900, shown inFIG. 9. In this embodiment, mast support plate 636 does not extendhorizontally and rearwardly from carrier 600, as far as the other mast100 horizontal supports, e.g., horizontal mast supports or struts 140.This construction allows the opening or space 136 for the BOP (see FIG.9), snubbing unit (see FIG. 11A), Christmas tree, well head, and/orother pressure control equipment. However, the mast construction is notintended to be limited to this arrangement.

In other words, Y-base 130 back most rail 138 is horizontally offsetcloser to carrier 600 than back most vertical mast supports 105 withrespect to carrier 600. Y-base 130 is sufficiently tall to allow BOPstacks to fit within opening or space 136. However, Y-base 130 isreplaceable and may be replaced with a higher or shorter Y-base asdesired. to accommodate the desired height of any pressure controland/or well head equipment. In this example, the bottoms of Y-base 130may be replaceably inserted/removed from Y-base receptacles 142 to allowfor easy removal/replacement of Y-base 130 from carrier 600.

As discussed hereinafter, vertical mast supports 105 support verticaltop drive guide rails 104 (see FIG. 4 B-B and FIG. 8 B-B), which guidetop drive 150. An optional raiseable/lowerable rig floor, such as rigfloor 102 (See FIG. 1) is not shown for viewing convenience.

FIG. 7 is a side elevational view of the carrier 600, the mast assembly100, the catwalk-pipe arm assembly 300, and the pipe tub 400 with themast assembly 100 (e.g., transporting a joint of pipe to the mastassembly 100 for engagement by the top drive) in a perpendicularrelationship with the carrier 600, and an arm to mast engagement element325 of the pivotal pipe arm 320 engaged with optional upper mast fixture135 on mast assembly 100 of the long lateral completion system 10 withrespect to one possible embodiment of the present disclosure. Theengagement of elements 325 and 135 may be utilized to provide an initialalignment of the pivotal connection of kick out arm 360 to pivotal pipearm 320. Kick out arm 360 is shown pivotally rotated to a verticalposition so that pipe 321 is aligned for connection with top drive 150,as discussed hereinafter. The carrier 600 is illustrated with the winchassembly 620 on the deck 602. The depicted hydraulic actuator 630 hasraised the mast assembly 100 into its vertical position, as discussedhereinbefore. The mast assembly 100 is illustrated with the top drive150 near the crown 190. The kickout arm 360 of the catwalk-pipe armassembly 300 may be more accurately vertically placed in the extendedposition adjacent to the mast assembly 100, having a kickout arm 360 inassociation therewith. As such, when the pipe arm 320 pivots into theposition shown in FIG. 7 (e.g., using the hydraulic cylinder 304), thepipe arm 320 is not parallel with the mast assembly 100, thus a joint ofpipe engaged with the pipe arm 320 would not be positioned suitably forengagement with the top drive 150. The kickout arm 360 is extendablefrom the pipe arm 320 into a position that is generally parallel withthe mast assembly 100, e.g., by use of a hydraulic actuator 362. Usingthe kickout arm 360, the pipe 321 is placed in the position which isessentially parallel with the mast assembly 100, and in this embodimentis positioned in the plane defined by mast rails 104 (See FIG. 4B-B),which guide top drive 150, by use of the hydraulic actuator 362. Themovement of the pivotal pipe arm 320 is provided by the hydraulicactuator 304.

In one possible embodiment, the upright position of pivotal pipe arm 320is controlled by angular sensors 325 and/or shaft position sensors 326(see FIG. 16A) to account for any variations in hydraulic operator 304operation.

Alternatively, or in addition, upper mast fixture 135 may comprise areceptacle and guide structure. In this embodiment, which may beprovided to guide the top of pivotal pipe arm 320 into contact with mast100, whereby the same vertical/side-to-side positioning of kick out arm360 is assured in the horizontal and vertical directions. The guideelements may, if desired, comprise a funnel structure that guides arm tomast engagement element 325 into a relatively close fitting arrangement.If desired, a clamp and/or moveable pin element (with mating hole inpivotal pipe arm) may be utilized to pin and/or clamp pivotal pipe arm320 into the same position for each operation. In another embodimentupper mast fixture may comprise a hydraulically operated clamp withmoveable elements that clamp the pipe in a desired position for alignedengagement with top drive threaded connector and/or guide member and/orclamp portion 163. As shown in FIG. 7A-A, upper fixture 135 may alsocomprise one or more pipe alignment guide members/clamps/supports asindicated at 139 to position pipe 321 and/or kickout arm 360 to therebyalign pipe 321 and pipe connector 323 with respect to top drive threadedconnector and/or guide member and/or clamp portion 163. Element 139 maycomprise a moveable hydraulic clamp or guide to affix and align the pipein a particular position. Element 139 may instead comprise a fixedgroove or slot or guide and may be hydraulically moveable to a laseraligned position.

As a result, top connector 323 on tubing pipe 321 is aligned to topdrive threaded connector and/or guide member and/or clamp portion 163,as discussed in more detail hereinafter, by consistent positioning ofkick out arm 360. It will be appreciated that rig to arm connectors 305further aid alignment by insuring that the distance between catwalk-pipearm assembly 300 and mast 100 remains constant.

FIG. 7A-A is a rear elevational view of FIG. 7 showing the mast assembly100 and top drive 150 of the long lateral completion system 10 withrespect to one possible embodiment of the present disclosure. FIG. 7A-Aillustrates the portion of the mast assembly 100, which includes the topdrive 150, and the upper portion of the pivotal pipe arm 320. Alsoillustrated are the lattice structural support elements 112 of the mastassembly 100. The top drive 150 is shown secured within a top drivefixture/carrier 151, which can be moved vertically along the mastassembly 100, e.g., via a rail/track-in-channel engagement usingrollers, bearings, etc. Due to the generally vertical orientation of themast assembly 100, and the positioning of the mast assembly 100 directlyover the wellbore, the top drive 150 can be directly engaged with themast assembly 100, via the top drive fixture 151, as shown, rather thanrequiring use of conventional cables, traveling blocks, and otherfeatures required when an angled mast is used. Engagement between thetop drive 150 and the mast assembly 100 via the top drive fixture 151eliminates the need for a conventional cable-based torque arm. Contactbetween the top drive 150 and the fixture 151 prevents undesiredrotation and/or torqueing of the top drive 150 entirely, using thestructure of the mast assembly 100 to resist the torque forces normallyimparted to the top drive 150 during operation.

FIG. 7B is a perspective view of the portion of the mast assembly 100and pivotal pipe arm 320 with clamps 370B engaged with upper fixture 135as illustrated in FIG. 7A-A of the long lateral completion system 10with respect to one possible embodiment of the present invention. Themast assembly 100 is illustrated with the top drive 150 positioned aselected distance the pipe arm 300.

FIG. 8 is a side elevational view of the completion system 10 in accordwith another embodiment of the present disclosure illustrating the mastassembly 100 in a perpendicular relationship with the carrier 600 and/oraligned with an axis of the upper portion of the wellbore. The carrier600 is shown with the deck 602 and the mast positioning hydraulicactuators 630 providing movement for the mast assembly 100 mast tocarrier pivot connection 634. The mast assembly 100 has the top drive150 disposed proximate to the crown 190. As discussed hereinafter, crown190 may comprise multiple pulleys that are utilized to raise and lowerthe blocks associated with top drive 150 utilizing drawworks 620. Thepipe arm 320 is extended in an upward position using the pipe armhydraulic actuator 304. Further, the kickout arm 360 is disposed in aparallel relationship with the mast assembly 100 using the kick out armhydraulic alignment actuator 362 to align pipe 321 appropriately withrespect to the mast assembly 100, e.g., in one embodiment the pipe ispositioned in the plane defined between mast top drive rails 104. Masttop drive rails 104 (shown in FIG. 8B-B) are secured to an inner portionof the two rear most (with respect to carrier 600) vertical supports 105of mast 100.

FIG. 8A-A shows another view of Y section 132, which comprises one ormore angled struts 134 on each side of mast 100 utilized to supportvertical mast supports 105. Pipe tong 170 is aligned within the planebetween guide rails 104 to thereby be aligned with top drive threadedconnector and/or guide member and/or clamp portion 163 (see FIG. 8B-Band FIG. 4B-B) of top drive 150

FIG. 8B-B is a rear elevational view of the mast assembly 100 and topdrive 150 of the long lateral completion system 10 (shown in FIG. 8)with respect to one possible embodiment of the present invention. FIG.8B-B illustrates the relationship of pivotal pipe arm 320, the top drive150 and the mast assembly 100. Further, the lattice support structure112 is illustrated for providing superior rigidity to and for the mastassembly 100.

FIG. 8C is a perspective view of FIG. 8B-B of the relationship betweenthe pivotal pipe arm 320 and the top drive 150 relative to the mastassembly 100 of the long lateral completion system with respect to onepossible embodiment of the present invention. Also illustrated is thepipe clamp 370 associated with the pivotal pipe arm 300 for holding ajoint of pipe. In an embodiment, a joint of pipe raised by the pipe arm300 then extended using the kickout arm 360 may require additionalstabilization prior to threading the pipe joint to the top drive.Additional pipe clamps along the mast assembly 100 can be used toreceive and engage the joint of pipe while the pipe clamp 370 of thepipe arm 300 is released, and to maintain the pipe directly beneath thetop drive 150 for engagement therewith.

Returning again to FIG. 8A-A, the figure depicts a sectional view ofFIG. showing the pipe tong 170 with respect to the mast assembly 100 ofthe long lateral completion system with respect to one possibleembodiment of the present invention. FIG. 8A-A illustrates therelationship of the hydraulic pipe tong 170 with respect to the mastassembly 100 and the base beam 120. The mast assembly 100 is supportedby braces 112. The braces 112 can be at various locations about thesystem 10 as one skilled in the art would appreciate.

FIG. 9 is an illustration of the long lateral completion system 10 ofthe present enclosure that depicts an embodied relationship of thecarrier 600, the mast assembly 100, catwalk-pipe arm assembly 300, thecatwalk 302 and a blowout preventer and snubbing stack 900 of the longlateral completion system 10 with respect to one possible embodiment ofthe present disclosure. As described previously, the mast assembly 100is disposed in a generally vertical orientation (e.g., perpendicular tothe earth's surface and/or the deck 602), such that the mast assembly100 is directly above the blowout prevent and snubbing stack 900 withthe wellbore therebelow. The recessed region at the base of the mastassembly 100 accommodates the blowout preventer and snubbing stack 900,while the top drive 150 disposed near the crown 190 of the mast assembly100 can move vertically along the mast assembly 100 while remainingdirectly over the well.

The mast assembly 100 can be moved and maintained in position by thehydraulic actuators 630 and/or other supports. The pipe arm 300 can bemoved and maintained in the depicted raised position via extension ofthe hydraulic actuator 304. The kickout arm 360 pivots from the top ofpivotal pipe arm using the hydraulic system 362 for aligning a joint ofpipe in alignment with the well and BOP and snubbing stack 900, whichmay utilize sensors 902, 904, 906, 908, for example, laser alignmentsensors 902 mounted on BOP and snubbing stack 900, 904 on kickout arm360, and/or laser alignment sensors 906 on top drive 150. It should beappreciated that the kick-out arm can be extended or retracted throughthe use of hydraulic system 362 and may be connected through manualactuation of hydraulic/pneumatics or through an electronic controlsystem, which maybe be operated through a control van or remotelythrough an Internet connection. This particular embodiment implementsthe use of a kick-out arm 360 to provide a substantially vertical jointof pipe for reception by the mast assembly 100, which may include a topdrive of some configuration. It is important that the joint of pipe besubstantially vertical so that the threads on each joint are notcross-threaded when the connection to the top drive is made.Cross-threading can lead to catastrophic failure of the connected jointsof pipe or damage the threads of the joint of pipe and render the jointof pipe unusable without extensive and costly repair. As mentionedabove, the pipe arm 300 can further include a centering guide, which iscapable of mating with a centering receiver located on the mast assembly100. This centering guide and centering receiver, when used provides anadditional point of contact between the pipe arm 300 and the mastassembly 100 providing additional stability to the system and moreprecise placement and orientation of the pipe arm and joints of pipe.

FIG. 9A-A is a sectional view of FIG. 9 illustrating the upper portionof the mast assembly 100 of the long lateral completion system 10 withrespect to one possible embodiment of the present invention. Onepossible embodiment of the relationship of the pipe arm 300 and theclamp 370 is shown. Also, the lattice support 112 for providing rigidityfor the mast assembly 100 is illustrated. The top drive 150 is retainedby the fixture 151, which is moveably disposed along the mast assembly100.

FIG. 9B is a perspective view of the upper portion of the mast assembly100 as illustrated in FIG. 9A-A, showing the top drive 150 and the uppermast fixture 135 of the long lateral completion system with respect toone possible embodiment of the present invention. The pipe arm 300 isshown below the top drive 150. The pipe clamp 370 enables removableengagement between pipe arm 300, and a joint of pipe, which said jointof pipe is engaged by the top drive 150, and alternately one or moreclamps or similar means of engagement along the mast assembly 100, orother engagement systems associated with the mast assembly 100 and/orthe top drive 150, can be used to assist with the transfer of the jointof pipe from the pipe arm 300 to the top drive 150.

FIG. 9C-C is a sectional view of FIG. 9 illustrating the relationship ofthe blowout preventer and snubbing stack 900 with respect to thecompletion system 10 of one possible embodiment of the presentinvention. The blowout preventer and snubbing stack 900 is showndirectly underneath the mast assembly 100, and thus directly adjacent tothe rig carrier, such that the hydraulic pipe tong 170 can beoperatively associated with joints of pipe added to or removed from astring within the wellbore. The mast assembly 100 can be secured usingthe adjustable braces 612 attached to the base plate 120. As anotherexample, mast top drive guide rails 104, which guide top drive 150 maybe aligned to be essentially parallel to the axis of the bore of BOP,within less than five degrees in one embodiment, or less than threedegrees, or less than one degree in another embodiment. Accordingly, topdrive threaded connector and/or guide member and/or clamp portion 163(See FIG. 4B-B) is also aligned to move up and down mast 100 essentiallyparallel or coaxial to the axis of the bore of BOP, within less thanfive degrees in one embodiment, or less than three degrees, or less thanone degree in another embodiment. The blowout preventer and/or otherpressure equipment may comprise pipe clamps and seals to clamp and/orseal around pipe as is well known in the art. As discussed hereinafter,a snubbing jack may comprise additional clamps and hydraulic arms formoving pipe into and out of a well under pressure, which is especiallyimportant when the pipe string in the hole weighs less than the force ofthe well pressure acting on the pipe, which would otherwise cause thepipe to be blown out of the well.

Specifically, the blowout preventer of the BOP and snubbing stack 900 isshown having a first set of rams 1012 positioned beneath a second set oframs 1014, the rams 1012, 1014 usable to shear and/or close about atubular string, and/or to close the wellbore below, such as duringemergent situations (e.g., blowouts or other instances of increasedpressure in the wellbore). Above the first and second set of rams 1012,1014, a snubbing assembly can be positioned, which is shown including alower ram assembly 1016 positioned above the rams 1014, a spool 1018positioned above the lower ram assembly 1014, an upper ram assembly 1020positioned above the spool 1018, and an annular blowout preventer 1022positioned above the upper ram assembly 1018. In an embodiment, theupper and lower ram assemblies 1020, 1016 and/or the annular blowoutpreventer 1022 can be actuated using hydraulic power from the mobilerig, while the first and second set of rams 1012, 1014 of the blowoutpreventer can be actuated via a separate hydraulic power source. Infurther embodiments, multiple controllers for actuating any of the rams1012, 1014, 1016, 1018 and/or the annular blowout preventer 1022 can beprovided, such as a first controller disposed on the blowout preventerand/or snubbing assembly and a second controller disposed at a remotelocation (e.g., elsewhere on the mobile rig and/or in a control cabin).During snubbing operations, the upper and lower ram assemblies 1020,1016 and/or the annular blowout preventer 1022 can be used to preventupward movement of tubular strings and joints, while during non-snubbingoperations, the upper and lower ram assemblies 1020, 1016 and annularblowout preventer 1022 can permit unimpeded upward and downward movementof tubular strings and joints. Typically, the annular blowout preventer1022 can be used to limit or eliminate upward movement of tubularstrings and/or joints caused by pressure in the wellbore, though if theannular blowout preventer 1022 fails or becomes damaged, or undernon-ideal or extremely volatile circumstances, the upper and lower ramassemblies 1020, 1016 can be used, e.g., in alternating fashion, toprevent upward movement of tubulars. As such, the depicted snubbingassembly (the ram assemblies 1020, 1018 and annular blowout preventer1022) can remain in place, above the blowout preventer, such thatsnubbing operations can be performed at any time, as immediately asnecessary, without requiring rental and installation of third partysnubbing equipment, which can be limited by equipment availability,cost, etc. In an embodiment, the upper and lower ram assemblies 1020,1018 can be used as stripping blowout preventers during snubbingoperations. Additionally, while the figures depict a single ram-typeblowout preventer in the BOP and snubbing stack 900 having two sets oframs 1012, 1014, in various embodiments, additional blowout preventerscould be used as safety blowout preventers, which can include pipeblowout preventers, blind blowout preventers, or combinations thereof.

Due to the clearance provided in the recessed region defined by theY-base 132 and support section 130, the snubbing assembly can remain inplace continuously, beneath the vertical mast, without interfering withoperations and/or undesirably contacting the top drive or other portionsof the mobile rig. Further, the clearance provided in the recessedregion can enable a compact snubbing unit (e.g., snubbing jacks and/orjaws) to be positioned above the annular blowout preventer 1022, such asthe embodiment of the compact snubbing unit 800, described below, anddepicted in FIGS. 11A through 11D.

FIG. 9C-C also shows a first hydraulic jack 1024A positioned at thelower end of the Y-base 132, on a first side of the rig, and a secondhydraulic jack 1024B positioned at the lower end of the Y-base 132, on asecond side of the rig. The hydraulic jacks 1024A, 1024B are usable toraise and/or lower a respective side of the rig to provide the rig witha generally horizontal orientation. For example, while FIG. 1 depicts anembodiment the long lateral completion system 10 having a mast assembly100 and a pipe handling system (e.g., skid 200, system 300, and tubs400) positioned at ground level, each component having a lower surfacecontacting the upper surface of the well (e.g., the earth's surface),the hydraulic jacks 1024A, 1024B can be used to maintain a ground levelrig in an operable, horizontal orientation, independent of the grade ofthe surface upon which the rig is operated.

FIG. 10A and FIG. 10B provide an illustration of one possible embodimentfor mounting pipe tong 170 utilizing the pipe tong fixture 172 tosupport pipe tong 170 at a desired vertical distance in mast 100 fromBOPs, such as the blowout preventer 900 shown in FIG. 9C-C, and withrespect to a co-axial orientation with respect to the bore of the BOPs.Pipe tongs 170 may be moved in/out and up/down. The pipe tong fixturecomprises one or more pipe tong vertical support rails 176, two pipetong horizontal movement hydraulic actuators 178 in association with ahorizontal pipe support 174 for displacing the pipe tong 170. It will beappreciated that fewer or more than two pipe tong horizontal movementhydraulic actuators 178 could be utilized. In this embodiment,horizontal support 174 may comprise telescoping and/or sliding portions,which engagingly slide with respect to each other, namely square outertubular component 175 and square inner tubular component 177, which moveslidingly and/or telescopingly with respect to each other. In thisembodiment, components 175 and 177 are concentrically mounted withrespect to each other for strength but this does not have to be thecase. Accordingly, pipe tong 170 is moved slidingly or telescopicallyhorizontally back and forth as shown by comparison of FIGS. 10A and 10B.In FIG. 10A, pipe tong 170 is shown in a first horizontal position movedlaterally away from pipe tong vertical support rails 176. In FIG. 10B,pipe tong 170 is shown in a second horizontal position moved laterallyor horizontally toward pipe tong vertical support rails 176. In thisway, pipe tong 170 can be moved in the desired direction to positionpipe tong 170 concentrically around the pipe from the bore through BOP900. It will be noted that here as elsewhere in this specification,terms such as horizontal, vertical, and the like are relevant only inthe sense that they are shown this way in the drawings and that forother purposes, e.g. transportation purposes as shown in FIG. 4 with therig collapsed and hydraulic tongs oriented vertically as compared totheir normal horizontal operation, hydraulic actuators 178 would thenmove pipe tong 170 vertically. It will also be understood that multipletongs may be utilized on such mountings, if desired, in otherembodiments of the invention, e.g. where a rotary drilling rig wereutilized with the pipe tong mounting on a moveable carrier. If desired,additional centering means may be utilized to move pipe tonghorizontally between vertical supports 176 to provide positioning inthree dimensions

FIG. 10B is a perspective view of the pipe tong fixture 172 asillustrated in FIG. 10A of the blowout preventer with respect to thecompletion system of one possible embodiment of the present inventionwhereby pipe tong 170 is moved vertically downwardly along pipe tongvertical support rails 176. Vertical sliding supports 179 permit pipetong frame 181, which comprise various struts and the like, to be movedupwardly and downwardly. Extensions 183 may be utilized in mountingsupport rails 176 to mast 100 and/or may be utilized with clampsassociated with vertical sliding supports 179 for affixing pipe tongframe 181 to a particular vertical position. Pipe tong frame 181 may belifted utilizing lifting lines within mast 100 and/or by connection withthe blocks and/or top drive 150 and/or by hydraulic actuators (notshown).

FIG. 11A, FIG. 11B, FIG. 11C, and FIG. 11D illustrate one possibleembodiment for a compact snubbing unit 800, usable with the completionsystem 10 of the present disclosure, e.g., by securing the snubbing unit800 above the blowout preventer and snubbing stack 900 (shown in FIG.9). However, snubbing unit 800 is simply shown as an example of asnubbing jack and other types of snubbing jacks may be utilized inaccord with the present invention. Generally, a snubbing jack will havea movable gripper, which may be mounted on a plate that is movable withrespect to a stationary gripper. At least one gripper will hold the pipeat all times. The grippers are alternately released and engaged to movepipe into and out of the wellbore under pressure. If not for this typeof arrangement, when the string is lighter than the force applied by thewell, the string would shoot uncontrollably out of the well. When thestring is lighter than the force applied by the well, this example ofsnubbing jack 800 can be utilized to move pipe into or out of the wellin a highly controlled manner, as is known by those of skill in the art.In another embodiment, an additional set of pulleys (not shown) might beutilized to pull top drive downwardly (while the existing cables remainin tension but slip at the desired tension to prevent the cables fromswarming) Once the pipe is heavier than the force of the well, then thenormal operation of top drive may be utilized for insertion and removalof pipe so long as the pipe string is preferably significantly heavierthan the force acting on the pipe string. In this example, the grippersof snubbing jack 800 also provide a back up in case of a sudden increasein pressure in the well. The compact (but extendable) snubbing unit 800can be sized to fit within the recessed region of the mast assembly 100,to prevent undesired contact with the mast assembly 100 even when thesnubbing jack is in an extended position. In this example, the depictedsnubbing unit 800 includes a first horizontally disposed plate member802, which is a vertically moveable plate, and a second horizontallydisposed plate member 804, which is a fixed plate with respect to thewellhead, displaced by vertical columns or stanchions 806 and 808. Thelower and/or possibly upper portion of columns or stanchions 806 and 808may comprise hydraulic jacks members which can be utilized forhydraulically moving plate member 802 upwardly and downwardly withrespect to plate member 804 and may be referred to herein as hydraulicjacks 806 and 808. Also, in this example, between the first member 802and the second member 804 is an intermediate member 803. In thisexample, between the first member 802 and the intermediate member 803 isa first engaging mechanism 820 for engaging and/or clamping and/oradvancing or withdrawing pipe. Between the intermediate member 803 andthe second member 804 is a second engaging mechanism 830 for engagingand advancing, or withdrawing pipe. In one embodiment, both plates 802and 803 are vertically moveable with respect to plate 804 whereby bothclamps (i.e., engaging mechanisms) 820 and 830 are used at the sametime. Accordingly, in one embodiment, both plates 802 and 803 movetogether. In another embodiment, grippers (i.e., engaging mechanisms)820 and 830 may be moveable with respect to each other. In one possiblemode of operation, the clamping mechanisms 820, 830 can be used to gripa joint of pipe and exert a downhole force or upward force thereto,counteracting a force applied to the string due to pressure in thewellbore. Because the force of the snubbing jack unit 800 is selected toexceed the pressure from the wellbore, joints can be added or removedfrom a completion string even under adverse, high pressure conditions.The BOPs or other control equipment, positioned below the snubbing jack800, can seal around the pipe as it is moved into and out of thewellbore by snubbing jack 800. Thus, grippers 820 and 830 may be engagedand hydraulic jacks within stanchions 806 and 808 may be expanded toremove pipe from the well or force pipe into the well. The hydraulicjacks may be contracted to move pipe into the well or pull pipe out ofthe well in a controlled manner. Other grippers within the BOPs may beutilized to hold the pipe, when grippers 820 and 830 are released andmoveable plates 802 and/or 803 are moved to a new position for graspingthe pipe to move the pipe into or out of the borehole as is known tothose of skill in the art. In one embodiment of the present invention,the computer control of the control van is utilized to control thegrippers 820, 830, and the hydraulic jacks 806 and 808, and othergrippers and seals in the BOPs to provide automated movement of the pipeinto or out of the wellbore. This movement may be coordinated with thatof the top drive and tongs for adding pipe or removing pipe. Thus, theentire process or portions of the process of going into the hole withsnubbing units may be automated. However, it will be understood that atleast two separate grippers or sets of grippers are required for asnubbing unit. If the top drive is connected to be able to apply adownward force then another stationary set of grippers is required. Inaddition, multiple sealing mechanisms such as rams, inflatable seals,grease injectors, and the like, may be utilized to open and close aroundsections of pipes so that larger joints and the like may be moved pastthe sealing mechanisms in a manner where at least one seal or set ofseals is always sealed around the pipe string in a manner than allowssliding movement of the pipe string. The control system of the presentinvention is programmed to operate the entire system in a coordinatedmanner. In addition to or in lieu of the snubbing unit 800 and/or thesnubbing assembly depicted and described above, various embodiments ofthe present system can include a full-sized snubbing unit, e.g., similarto a rig assist unit.

FIG. 12A depicts a schematic view of an embodiment of a control cabin702 of the long lateral completion system 10 with respect to the presentdisclosure. The control cabin 702 comprises a command station 710. Thecommand station 710 comprises a seat 712, control 714, monitor 716 andrelated control devices. Further, the control cabin 702 provides for asecond seat 715 in association with a monitor, and, optionally, astructure for supporting other related monitoring and/or controlactivities 722, 724, and a third seat 718 in association with yetanother monitor. The control cabin 702 has doors for exiting the cabinarea and accessing a walkway 720 disposed around the perimeter of thecontrol cabin 702.

In one embodiment, command station 710 is positioned so that oncecontrol van 700 is oriented or positioned with respect to mast 100 (SeeFIG. 1), carrier 600, catwalk and pipe handling assembly 300, and/orpump/pit 500, then all mast operations can be observed through commandstation front windows 730 as well as command station top windows 732.Front windows 730, for example, allow a close view of rig operations atthe rig floor. Top windows 732 allow a view all the way to the top ofmast 100. In one embodiment, additional command station side and rearwindows 740, side windows 742 (depicted in FIG. 12C), 744 (depicted inFIG. 12D) will allow easy observation of other actions around mast 100.If desired, control van 700 may be positioned as shown in FIG. 1 and/oradjacent pump/pit combination skid 500. If desired, additional camerasmay be positioned around the rig to allow direct observation of othercomponents of the rig, e.g., pump/pit return line flow or the like.

The control van 700 may include a scissor lift mechanism to lift andadjust the yaw of command station 710. A scissor lift mechanism is adevice used to extend or position a platform by mechanical means. Theterm “scissor” is derived from the mechanism used, which is configuredwith linked, folding supports in a crisscrossed “X” pattern. Anextension motion or displacement motion is achieved by applying a forceto one of the supports resulting in an elongation of the crossingpattern supports. Typically, the force applied to extend the scissormechanism is hydraulic, pneumatic or mechanical. The force can beapplied by various mechanisms such as by way of example and withoutlimitation a lead screw, a rack and pinion system, etc.

For example with loading applied at the bottom, it is readily determinedthat the force required to lift a scissor mechanism is equal to the sumof the weights of the payload, its support, and the scissor armsthemselves divided by twice the tangent of the angle between the scissorarms and the horizontal. This relationship applies to a scissor liftmechanism that has straight, equal-length arms, i.e., the distance froman actuator point to the scissors-joint is the same as the distance fromthat scissor-joint to the top load platform attachment. The actuatorpoint can be, by way of examples, a horizontal-jack-screw attachmentpoint, a horizontal hydraulic-ram attachment point or the like. Forloading applied at the bottom, the equation would be F=(W+Wa)/2 Tan Φ.The terms are F=the force provided by the hydraulic ram or jack-screw,W=the combined weights of the payload and the load platform, Wa=thecombined weight of the two scissor arms themselves, and is the anglebetween the scissor arm and the horizontal.

And for loading applied at the center pin of the crisscross pattern, theequation would be F=W+(Wa/2)/Tan Φ. The terms are F=the force providedby the hydraulic ram or jack-screw, W=the combined weights of thepayload and the load platform, Wa=the combined weight of the two scissorarms themselves, and is the angle between the scissor arm and thehorizontal.

FIG. 12B is an elevation view of the control cabin 702 of the completionsystem 10 of one possible embodiment of the present invention. Thecommand station 710 the walkway 720 and exterior controls 726.

FIG. 12C is an end view of the control cabin 702 of the completionsystem 10 of one possible embodiment of the present invention. FIG. 12Cillustrates the command station 710 in association with the controlcabin 702. The walkway 720 is also illustrated.

FIG. 12D is an end view of the control cabin 702 taken from thealternate perspective as that of FIG. 12C of the completion system ofone possible embodiment of the present invention. The outer controls 726are illustrated.

FIG. 13 is an illustration of the carrier 600 adapted for use with thecompletion system 10 of one possible embodiment of the presentinvention. The carrier comprises a cabin 605, a power plant 650, and adeck 610. Foldable walkway 602 folds up for transportation and then whenunfolded extends the walkway space laterally to the side of carrier 600.Winch assembly 620 can be mounted along slot 622 at a desired axialposition at any desired axial position along the length of carrier 600.Winch or drawworks assembly 620 may or may not be mounted to a mountingsuch as mounting 624, which is securable to slot 620. Mounting 624 maybe utilized for mounting an electrical power generator or other desiredequipment. Recess 626 may be utilized to support mast positioninghydraulic actuators 630, which are not shown in FIG. 13. One or morestanchions 614 (e.g., a Y-base) are illustrated for engaging the mastassembly 100 with the carrier 600, wherein the mast can be supported bycarrier to mast pivot connection 634 and at the carrier 600 rearmostposition by mast support plate 363 (also shown in FIG. 4 as 636).

FIG. 14 is an illustration of the catwalk-pipe arm assembly 300 of thecompletion system 10 of one possible embodiment of the presentinvention. The catwalk-pipe arm assembly 300 is illustrated with aground skid 310, pipe arm hydraulic actuators 304 for lifting thepivotal pipe arm 320 and the kickout arm 360 attached thereto. Thekickout arm 360 can subsequently be extended the central pipe arm 320using additional hydraulic cylinders disposed therebetween.

In yet another embodiment, a pivotal clamp could be utilized at 312 inplace of the entire kick arm 360 whereby orientation of the pipe forconnection with top drive 150 may utilize upper mast fixture 135 and/ormast mounted grippers and/or guide elements.

In one embodiment, catwalk 302 may be provided in two elongate catwalksections 309 and 311 on either side of pivotal pipe arm 320 for guidingpipe to and/or away from pivotal pipe arm 320. However, only oneelongate section 309 or 311 might be utilized. Catwalk 302 provides awalkway and a catwalk is often part of a rig, along with a V-door, forlifting pipes using a cat line. To the extent desired, catwalk 302 maycontinue provide this typical function although in one possibleembodiment of the present invention, pivotal pipe arm 320 is nowpreferably utilized, perhaps or perhaps not exclusively, for theinsertion and removal of tubing from the wellbore.

In one possible embodiment of catwalk 302, each catwalk section 309 and311 may comprise multiple catwalk pipe moving elements 314 which movethe pipes toward or away from pivotal pipe arm 320 and otherwise are ina stowed position, resulting in a relatively smooth catwalk walkway.Referring to FIGS. 15F and F 15G, FIG. 21A, and FIG. 21B, catwalk pipemoving hydraulic controls 333 may be utilized to independently tiltcatwalk pipe moving elements 314 upwardly or downwardly, as indicated.On the left of FIG. 15F, catwalk pipe moving element 314 is in thestowed position flat with catwalk 309. On the right of FIG. 15F, catwalkpipe moving element 314 is tilted inwardly to urge pipes toward pivotalpipe arm 320. In FIG. 15G, catwalk pipe moving elements are both tiltedaway from pipe moving element 314 to urge pipes away from pivotal pipearm 320. However, each group of catwalk pipe moving elements 314 on eachof catwalks 309 and 311 operate independently. In one embodiment, bytilting pipe moving elements 314 away from pivotal pipe arm 320, thepipe moving elements 314 operate in synchronized fashion with pipeejector direction control which directs pipe away from pipe arm 320 in adesired direction as indicated by arrows 377A and 377B (see FIG. 17), asdiscussed hereinafter.

In another embodiment, each entire elongate catwalk section 309 and 311could be pivotally mounted on skid edges 301 and 307. Accordingly, dueto the pivotal mounting discussed previously or in accord with thisalternate embodiment, catwalk sections 309 may be selectively utilizedto urge pipes toward or away from pivotal pipe arm 320. However, in yetanother embodiment the catwalks may also be fixed structures so as toeither slope towards or away from pivotal arm 320 or may simply berelatively flat.

In yet another embodiment, at least one side of catwalk 302 (catwalksections 309 and/or 311) may be slightly sloped inwardly or downwardlytoward pivotal pipe arm 320 to urge pipe toward guide pipe forengagement with pivotal pipe arm 320. In one embodiment, pipe tubs 400and/or one or both sides of catwalk 302 (and/or catwalk pipe movingelements 314) include means for automatically feeding pipes onto catwalk302 for insertion into the wellbore, which operation may be synchronizedfor feeding pipe to or ejecting pipe from pivotal pipe arm 320. Inanother embodiment, at least one side of catwalk 302 and/or catwalk pipemoving elements 314, may also be slightly sloped slightly downwardlytowards at least one of pipe tubs 400 to urge pipes toward therespective pipe tub when pipe is removed from the well. In oneembodiment, one pipe tub may be utilized for receiving pipe whileanother is used for feeding pipe. In another embodiment, catwalk 302 maysimply provide a surface with elements (not shown) built thereon forurging the pipe to or from the desired pipe tub 400.

In yet another embodiment, catwalk 302, which may or may not bepivotally mounted and/or comprise catwalk pipe moving elements 314, maybe provided as part of the pipe tub and may not be integral or builtonto the same skid as pivotal pipe arm 320. In yet another embodiment,the pipes may be manually fed to and from the pipe tubs or pipe racks topivotal pipe arm 320 via catwalk 302.

FIG. 14A is a blowup view of the lower pipe arm pivot connection 313upon which the pivotal pipe arm 320 is lifted for the catwalk-pipe armassembly 300. The lower pipe arm pivot connection 313 comprises abearing 306 and a shaft or pin 308 which provides a pivot point for thepivotal pipe arm 320 with respect to the pipe arm ground skid 310.

FIG. 15A is an elevation view of the catwalk-pipe arm assembly 300 ofthe completion system 10 of one possible embodiment of the presentinvention. The catwalk-pipe arm assembly 300 comprises the central arm320, a kickout arm 360 and one or more clamps 370A, 370B, 370C forengaging a pipe “P.” The catwalk-pipe arm assembly 300 is rotationallymoved or pivoted with respect to lower pipe arm pivot connection 313using the hydraulic actuators 304. In this embodiment, pivotal pipe arm320 comprises a grid comprising plurality of pipe arm struts 364.

FIG. 15B is an enlarged or detailed view of the section “B” of pivotconnection 313 as illustrated in FIG. 15A of the completion system ofone possible embodiment of the present invention. The pivotal pipe arm320 is pivotally moved using a bearing 306 in association with a shaftor pin 308. Control arm 315, to which pivot arm struts 317 (See alsoFIG. 15A) are affixed, pivots about lower pipe arm pivot connection 313.

FIG. 15C is an enlarged or detailed view of section “C” illustrated inFIG. 15A of the completion system of one possible embodiment of thepresent invention, which shows control arm to hydraulic arm pivotconnection 319. Piston 323 of the hydraulic cylinder of hydraulicactuator 304 is pivotally engaged with control arm 315 using the pin327.

FIG. 15D is an enlarged or detailed view of the section indicated by “D”in FIG. 15A of the completion system of one possible embodiment of thepresent invention, which shows the hydraulic cylinder of hydraulicactuator 304 pivotal connection 329. FIG. 15D shows the engagement ofthe hydraulic cylinder with the skid using the pin 331.

FIG. 15E is a plan view of the catwalk-pipe arm assembly 300 of thecompletion system 10 of one possible embodiment of the presentinvention. The catwalk-pipe arm assembly 300 comprises the pivotal pipearm 320 in association with the skid 310. The arm has engaged with it akickout arm 360 which is pivotally moved with the hydraulic actuator362. The pivotal pipe arm 320 is pivotally moved with the hydraulicactuator 304. The kickout arm has clamps 370A, 370B for engaging a pieceof pipe “P.”

FIG. 16A is an elevation view of the pivotal pipe arm 320 of thecompletion system 10 of one possible embodiment of the presentinvention, without the catwalk 302 for easier viewing. Pivotal pipe arm320 comprises an elongate lower pipe arm section 322 which is pivotedusing the hydraulic actuators 304. Lower pipe arm section 322 is securedto y-joint connector 324, which in turn connects to pivot arm Y armstrut components 326A and 326B (depicted in FIG. 16B). The Y arm strutcomponents 326A and 326B are connected to control arms 315, which are inmoveable engagement with the hydraulic actuators 304. An extension (notshown) may be utilized to engage upper mast fixture 135, if desired, toprovide a preset starting position from which kickout arm 360 pivotsoutwardly to align with the top drive 150.

The elongate kickout arm 360 secures a piece of pipe “P” using aplurality of pipe clamps 370, which are labeled 370A and 370B at thebottom and top (when upright) of kickout arm 360. Pipe ejector directioncontrol 371 acts to eject the pipe from pivotal arm 320 in a desireddirection when the pipe is laid down adjacent catwalk 302, as discussedhereinafter.

FIG. 16B is a plan view of the pivotal pipe arm 320, as illustrated inFIG. 16A for the completion system 10 of one possible embodiment of thepresent invention, showing only the pipe arm components for convenience.In one possible embodiment, upper pipe arm section 340 may alsoincorporate kickout arm 360. In this embodiment, kickout arm 360 remainsgenerally parallel to pivotal pipe arm 320 except when pivotal pipe arm320 is moved into the upright position shown in FIG. 7, FIG. 8, and FIG.9. Upon reaching the upright position, kickout arm 360 is pivoted usingthe hydraulic actuators 362, which cause kickout arm 360 to pivot awayfrom pipe arm 360 about kickout arm pivot connection 312 (FIG. 16C) atthe top of pivotal pipe arm 320. The kickout arm 360 is shown with theclamps 370A and 370B at the bottom and top (when vertically raised) ofkickout arm 360 as well as pipe ejector direction control 371, which maybe positioned more centrally, if desired.

FIG. 16C is an enlarged or detailed view of the section “C” asillustrated in FIG. 16A for the completion system 10 of one possibleembodiment of the present invention, which shows kick arm pivotconnection 312 (FIG. 16C) at the top of pivotal pipe arm 360. FIG. 16Cshows the pivotal pipe arm 320 in association with an upper portion ofkickout arm 360 (when vertically raised) and the clamp 370B.

FIG. 16D is an end view of the pivotal pipe arm 320 and kickout arm 360of the completion system 10 of one possible embodiment of the presentinvention for the completion system 10, which shows an end view kickoutarm pivot connection 312 (FIG. 16C) at the top of pivotal pipe arm 320and clamp 370B. Pivot beam 366 connects pipe kickout arm 360 to the topof pivotal pipe arm 320. Kickout arm base 375 may comprise a rectangularcross-section in this embodiment. The pipe is received into pipereception groove 378.

FIG. 17 is a perspective view of a portion of the kickout arm 360 of thecompletion system 10 of in accord with one possible embodiment of thepresent invention. The kickout arm 360 is illustrated with thecomponents attached to a kick out arm base 375, which in this embodimentmay have a relatively rectangular or square profile. The kick out armbase 375 is used for supporting one possible embodiment of the pipeclamps 370A and 370B (See also FIG. 18A) and pipe ejector directionalcontrol 371. Torsional arms 372, which are also referred to as torsionalarms 372A and 372B, are utilized to selectively activate eject arms 374Aand 374B. The eject arms 374A connect to torsional arms 372A. The ejectarms 374B connect to torsional arms 372B, respectively. When torsionalarms 372A are rotated utilizing hydraulic actuator 382A, which rotatesplates 384A, (see FIG. 17A and FIG. 18 C-C), then eject arms 374A willlift the pipe to eject the pipe from kickout arm 360 in the directionshown by pipe ejection direction arrow 377A to the pipe tub or the like.Similarly, when torsional arms 372B are rotated, then eject arms 374Beject the pipe in the direction indicated by pipe ejection directionarrow 377B to the other side. Prior to ejection or clamping, the pipewill align with the pipe reception grooves 378 in the clamps 370 andejector mechanism 380. Plates 375 comprise a relatively squarereceptacle 385 (see FIG. 17A) that mates to kick out arm base 375 forsecure mounting to resist torsional forces created during pipe ejectionand/or pipe clamping.

FIG. 17A and FIG. 18C-C provide an enlarged or detailed view of the pipeejector direction control 371 illustrated in FIG. 17 for the completionsystem of one possible embodiment of the present invention. The pipeejector direction control 371 is illustrated using the plates 376, whichmay be connected by a bracket 386, in association with the torsionalejection rods 372A and 372B. The ejection mechanisms 380A and 380B (seeFIG. 18 C-C) are between the plates 376 and provides for rotationalmovement of the torsional ejection rods 372A and 372B. Ejectionmechanism 380A operates to eject pipe as indicated by pipe ejectiondirection arrow 377A (see FIG. 17). Ejection mechanism 380B operates toeject pipe in the direction indicated by arrow 377B. The pipe receptiongroove 378 is for accepting the joint of pipe during clamping or priorto ejection. In this embodiment, ejector hydraulic actuators 382A and382B are pivotally connected to pivotal plates 384A and 384B,respectively, which are fastened to respective torsional ejection rods372A and 372B for selectively ejecting the pipe from kickout arm 360 inthe desired direction as indicated by pipe ejection arrows 377A and377B. As shown in FIG. 17, torsional ejection rods 372A and 372B arerotationally mounted to plates on clamps 370A and 370B for support atthe ends thereof.

Referring to FIG. 17, FIG. 18C, FIG. 21A, and FIG. 21B, clamps 370A and370B are similar and in this embodiment each comprises two sets ofclamping members, lower clamp set 387A,B and upper clamp set 389 A,B.Each clamp set is activated by respective pairs of clamp hydraulicactuators, such as 392A and 392B, perhaps best shown in FIG. 18A. Inthis embodiment, after the pipe is rolled into the pipe receptiongrooves, then the clamp sets 387A, 389A and 387B, 389B are pivotallymounted on clamp arms 394A and 394B to rotate upwardly around pivotconnections to clamp the pipes. When not in use clamp sets 387A, 389Aand 387B, 389B are rotated downwardly to be out of the way (as shown inFIGS. 17 and 21A) as the pipes are rolled into the pipe receptiongrooves 378.

It will be appreciated that other types of clamps, arms, ejectionmechanisms and the like may be hydraulically operated to clamp and/oreject the pipe onto or away from kickout arm 360.

FIG. 18A is an elevation view of the kickout arm 360 of the completionsystem 10 in accord with one possible embodiment of the presentinvention. The kickout arm 360 is shown with the lower and upper pipeclamps 370A and 370B, pipe ejector direction control 371, base 375 withtorsional ejection rod 372A (depicted in FIG. 18B), ejector hydraulicactuator 382A, and pipe clamp hydraulic actuators 392A.

FIG. 18B is a bottom view of the kickout arm 360 as illustrated in FIG.18A for the completion system of one possible embodiment of the presentinvention. FIG. 18B illustrates the base 375 in association with thetorsional ejection rods 372A and 372B, which in this embodiment arerotationally secured to each of clamps 370A and 370B as well as to pipeejector direction control 371. The clamps 370A and 370B are dispersed atthe remote ends of the kickout arm 360. There may be fewer or moreclamps, as desired.

FIG. 18C is a top view of the kickout arm 360 of the completion system10 of the present invention. The kickout arm 360 is illustrated with theclamps 370A and 370B secured with the base 375 and operativelyassociated with the torsional ejection rods 372A and 372B.

FIG. 18B-B is a sectional view FIG. 18B for the completion system of onepossible embodiment of the present invention. The end 390 is illustratedwith kick arm pivot connection 312 at the top (when pivotal pipe arm isupright) of pivotal pipe arm 320.

FIG. 18C-C is a cross section of FIG. 18C illustrating pipe ejectordirection control 371. The ejector mechanism 380A and 380B compriseejector hydraulic actuators 382A, 382B and pivotally mounted ejectioncontrol arms 384A and 384B, which rotate torsional ejection rods 372A,and 372B in one possible embodiment of the present invention.

FIG. 19A is an elevation view of the top drive fixture 151, without thetop drive mechanism 160, used in conjunction with the mast assembly 100of the completion system 10 of one possible embodiment of the presentinvention. The top drive fixture 151 is shown with the guide frame 152,separated designated as 152A, 152B. Guide frames 152A, 152B areconnected at top drive fixture flanges 141A, 141B to extensions 143A,143B downwardly projecting from side plates 156A, 156B of a travelingblock frame 154. Traveling block fixture 154 is part of a travelingblock assembly 153 comprising frame 154 and a cluster of sheaves 155A,155B, 155C, 155D supported in such frame. Guide frames 152A, 152Bslidingly engage mast top drive guide rails 104, as discussedhereinbefore.

FIG. 19B is a side view of the top drive fixture 151 and frame 154 ofthe traveling block assembly 153 illustrated in FIG. 19A. FIG. 19Billustrates the guide frame 152B in relation to the traveling blockframe 154B using the block side plate 156B.

FIG. 19C-C is a cross sectional view taken along the section line C-C inFIG. 19B illustrating the mechanism associated with the top drivefixture 151 of the completion system of one possible embodiment of thepresent invention. The mechanism provides for the slide supports 152having at its extremities a first and second rollers 158A, 158B on arespective roller axles 159A, 159B of guide frame 152B, which may beutilized to provide a rolling interaction with mast top drive guiderails 104 maintaining the top drive in a relatively fixed verticalposition. FIG. 19C-C also depicts flange 141B connected to extension143B.

FIG. 19D is an enlarged or detailed view of the roller 158A asillustrated in FIG. 19B.

FIG. 19E-E is a cross sectional view taken along the section line E-E inFIG. 19A. 19E-E is in the same orientation as FIG. 19B, but issectional. Referring to FIGS. 19A, 19B and 19E-E, traveling block frame154 further comprises a front plate 144A, a rear plate 144B (depicted inFIG. 19B), and side plates 156A, 156B including the downwardlyprojecting extensions 143A, 143B. A frame cross member spans side plates156A, 156B above traveling block sheaves 155A, 155B, 155C, 155Dsufficiently within parallel planes tangent to peripheries of flanges ofsuch sheaves that a drilling line reeved around the sheaves as describedbelow does not contact cross member. Cross member mounts inferiorly aplurality of rigid spaced apart parallel hangers 146A, 146B, 146C, 146Dand 146E (depicted in FIG. 19A), each in a plane perpendicular to anaxis of front sheaves of a crown block assembly described below. Hangers146A, 146B support between them an axle 147A for traveling block sheave155A; hangers 146B, 146C support between them an axle 147B for travelingblock sheave 155B; hangers 146C, 146D support between them an axle 147Cfor traveling block sheave 155C; and hangers 146D, 146E support betweenthem an axle 147D for traveling block sheave 155D. Each sheave axle147A, 147B, 147C and 147D is parallel to the plane of the axis of thefront sheaves of the crown block assembly. Traveling block sheaves 155A,155B, 155C, 155D rotate in traveling block frame respectively on axles147A, 147B, 147C and 147D.

FIG. 20A is an illustration of the top drive 150 in the top drivefixture 151 of the completion system of one possible embodiment of thepresent invention. The top drive comprises the top drive fixture 151 inconjunction with the drive mechanism 160. The drive mechanism 160 ismoveably engaged with the guide frames 152A, 152B and moves in avertical direction using traveling block assembly 153. A top drive shaft165 provides rotational movement of the pipe using the drive mechanism160. Top drive shaft 165 connects to item 163, which may comprise a topdrive threaded connector and/or pipe connection guide member. Item 163may also be adapted to hold the pipe. A torque sensor may also beincluded therein.

FIG. 20B is an upper view of traveling block assembly 153 and top drive150 as illustrated in FIG. 20A. FIG. 20B illustrates the guide frames152A, 152B with the frame 154 there between.

Referring to FIGS. 19A, 19B, 19E-E, 20A and 20B, traveling block sheaves155 are seen to be horizontally canted in frame 154. The purpose andangle of this canting and the operation of the traveling block assemblyto raise and lower top drive 150 is now explained.

Referring now to FIGS. 4, 7B, 9, 27A, and 27B, carrier 600 pivotallymounts mast 100 on the carrier for rotation upward to an erect drillingposition, as has been described. Mast 100 comprises front and rearvertical support members 105, and a mast top or crown 190 supported atopfront and rear vertical support members 105. Drawworks 620 is mounted oncarrier 600 to the rear of an erect mast 100. Drawworks 620 has a drum621 with a drum rotation axis perpendicular to the drilling axis forwinding and unwinding a drilling line on drum 621. A crown blockassembly 191 is mounted in mast top or crown 190 for engaging thedrilling line. The crown block assembly comprises a cluster 193 of frontsheaves mounted at the front of mast top 190 facing the drilling axis.This cluster 193 comprises first and second outermost sheaves and atleast one inboard sheave, all aligned on an axis in a planeperpendicular to the drilling axis and having a predetermined distancebetween grooves of adjacent front sheaves. A fast line sheave 194 ismounted on the drawworks side of the mast top behind the first outermostfront sheave of cluster 193 and on an axis substantially parallel to theaxis of the front sheaves of cluster 193, for reeving the drilling lineto the first outermost front sheave of cluster 193. A deadline sheave195 (blocked from view by the front sheaves of cluster 193) is mountedon the drawworks side of mast top 190 behind a second laterallyoutermost front sheave (blocked from view by fast line sheave 194) andon an axis substantially parallel to the axis of the front sheaves ofcluster 193, for reeving the drilling line from the second outermostfront sheave to an anchorage.

Traveling block assembly 153 hangs by the drilling line from the frontsheaves of the crown block assembly, and comprising, as has beendescribed, fixture 154 and the cluster of sheaves 155 supported in thefixture. The cluster is one less in number than the number of frontsheaves in the crown block assembly and includes at least first andsecond outermost traveling block sheaves 155A, 155D (in the illustratedembodiment there are two traveling block sheaves, 155B, 155C inboard ofoutermost traveling block sheaves 155A, 155D. Traveling block sheaves155A, 155B, 155C, 155D have a predetermined distance between grooves ofadjacent traveling sheaves and rotate on a common horizontal axis in aplane perpendicular to the drilling axis. The axis of the travelingsheaves 155A, 155B, 155C, 155D is angled in the latter plane relative tothe axis of the front sheaves of the crown block assembly such that thedrilling line reeves downwardly from the groove in a first front sheaveparallel to the drilling axis to engage the groove in a first travelingblock sheave and reeves upwardly from the groove in a first travelingblock sheave toward the second front sheave next adjacent such firstfront sheave at an up-going drilling line angle to the drilling axiseffective according to the distance between the grooves of the first andsecond front sheaves to move the drilling line laterally relative to thefront sheave axis and engage the groove of the second front sheave, eachthe traveling block sheaves receiving the drilling line parallel to thedrilling axis and reeving the drilling line to each following frontsheave at an up-going angle.

Accordingly, first outermost traveling block sheave 155A receives thedrilling line reeved downward from the first laterally outermost frontsheave of the crown block assembly parallel to the drilling axis andreeves the drilling line at an up-going angle to a next adjacent inboardfront sheave. The latter inboard front sheave reeves the drilling linedownward to traveling block sheave 155B next adjacent first laterallyoutermost traveling block sheave 155A parallel to the drilling axis. Thelatter traveling block sheave 155B reeves the drilling line at anup-going angle to a front sheave next adjacent the front sheave nextadjacent the first laterally outermost front sheave, and so forth, foreach successive traveling block sheave (respectively sheaves 155C, 155Din the illustrated embodiment of FIGS. 19A, 19B, 19E-E, 20A and 20B),until the second outmost traveling block sheave (155D in the illustratedembodiment) reeves the drilling line at an the up-going angle to thesecond outmost front sheave. The second outmost front sheave reeves thedrilling line to the deadline sheave, and the deadline sheave reeves theline to the anchorage.

In an embodiment, an up-going angle from a traveling block sheave to acrown block front sheave is not more than about 15 degrees. In anembodiment, an up-going angle from a traveling block sheave to a crownblock front sheave is about 12 degrees.

In an embodiment, the predetermined distances between grooves of thefront sheaves are equal from sheave to sheave. In an embodiment in whichthe front sheaves comprise a plurality of inboard sheaves, thepredetermined distance between at least one pair of inboard frontsheaves may be the same or different than the distance separating anoutermost front sheave from a next adjacent inboard front sheave.

FIG. 20A-A is a cross sectional view taken along the section line A-A inFIG. 20A illustrating the relationship of the drive mechanism 160 in thetop drive frame 151. The guide frames 152 provide structural support forthe drive mechanism 160.

FIG. 21A is a perspective view of the pipe arm assembly with the pipeclamps recessed allowing the pipe arm to receive pipe, as alsopreviously discussed with respect to FIG. 17, and FIG. 18C. In thisembodiment, pipe ejector direction control 371 is omitted for clarity ofthe other elements in the figure. However, in another possibleembodiment, the pipe ejector mechanism may not be utilized or may bereplaced by other pipe ejector means. Kickout arm 360 is secured topivotal pipe arm 320 at kickout arm pivot connection 312 located at thetop of pivotal pipe arm 320. Kickout arm hydraulic actuators 362 providepivotal movement when pipe arm 320 is in an upright position. In thisembodiment, pipe clamps 370A and 370B are mounted to kickout arm 360,although in other embodiments pipe clamps 370A and 370B can be mounteddirectly to pivotal pipe arm 320. Catwalk segments 309 and 311 containone possible embodiment of catwalk pipe moving elements 314 to urge pipeonto pipe arm 320 which are guided or rolled into pipe reception grooves378 along pipe guides 379 (See FIG. 16D). Pipe clamp sets 387A, 389A and387B, 389B are recessed below an outer surface of pipe guides 379 withinpipe clamp mechanisms 370A and 370B to allow pipe P to be accepted inpipe reception grooves 378, such as pipe P which is shown in position inthe pipe reception grooves. Pipe clamp sets 387A, 389A and 387B, 389Bare mounted to pivotal pipe clamp arms 394A and 394B.

FIG. 21B is a perspective view of the pipe arm assembly with the pipeclamps engaged around the pipe, which allows the pipe arm to move thepipe P to an upright position in mast 100. In this embodiment, pipeclamp 370A is located at a lower point on kickout arm 360, while pipeclamp 370B is located on an upper part of kickout arm 360. In anotherembodiment, pipe clamps 370A and 370B could be mounted to pipe arm 320.As discussed hereinbefore, pipe clamp sets 387A, 389A and 387B, 389B aremounted to pivotal pipe clamp arms 394A and 394B. In this embodiment,once pipe P is urged into pipe receptacle grooves 378 by catwalk movingelements 314 on either catwalk section 309 or 311, pipe clamp hydraulicactuators 392A and 392B (See FIG. 18C) urge pipe clamp sets 387A, 389Aand 387B, 389B around clamp pivots 391A and 391B to engage pipe P.

FIG. 22A is a perspective end view of one possible embodiment of walkway309 and 311 with one possible example moving elements, illustrating howpipe is moved from the walkway to the pipe arm. In FIG. 22A, catwalksegment 311 contains catwalk pipe moving elements 314 in a slopedposition for urging pipe P into pipe clamp mechanisms 370A and 370Butilizing pipe reception grooves 378. In another embodiment, catwalkpipe moving elements 314 can move into a second sloped position formoving pipe away from kickout arm 360 towards a pipe tub. In thisembodiment, corresponding pipe moving element hydraulic controls 333 canbe utilized for selectively operating pipe moving elements 314 oncatwalk segments 309 and 311(See FIG. 15F). For example, the movingelements can be retracted below the surface of walkway 311 or raised toprovide a gradual slope that urges the pipes into pipe reception grooves378.

In one possible embodiment, pipe barrier posts 316 may be utilized toprevent additional pipes from entering catwalk segment 311 while pipe isbeing moved with pipe moving elements 314 towards pipe clamp mechanisms370A and 370B located on kickout arm 360. Pipe barrier posts 316 maykeep the pipe outside of the catwalk segment 311 after pipe movingelements 314 are lowered, whereby an operator may walk along the catwalkwithout impediments and/or utilize the catwalk for other purposes suchas making up tools or the like. Catwalk segment 309 illustrates pipemoving elements 314 in a flat position flush with the surface of catwalksegment 309. In one possible embodiment, pipe barrier posts 316 may behydraulically raised and lowered. In another embodiment pipe barrierposts 316 may mechanically inserted, removed, or replaced (such as withsockets in the catwalk). In another embodiment, pipe barrier posts maynot be utilized. In another embodiment, other means for separating thepipe may be utilized to urge a single pipe on pipe moving elementswhereupon catwalk moving elements 314 are raised to gently urge one ormore pipes into pipe reception grooves 378. Catwalk pipe moving elementsmay be larger or wider if desired. In another embodiment, catwalk pipemoving elements may comprise a groove that holds the next pipe untilraised whereupon the pipes are urged toward pipe guides 379 and pipereception grooves 379.

FIG. 22B is a perspective end view of the walkway with movable elementsin accord with one possible embodiment of the invention. Catwalk segment309 contains pipe moving elements 314 in a recessed position with pipebarrier posts 316 to prevent pipe from entering catwalk segment 309while pipe P is engaged with pivotal pipe arm 320. In this embodiment,catwalk segment 311 illustrates pipe moving elements 314 in a raisedposition that work with pipe barrier posts 316 to prevent pipe fromentering catwalk segment 311. In other embodiments, pipe barrier posts316 may be hydraulically actuated or manually removable. In anotherembodiment, pipe barrier posts may be omitted and pipe moving elements314 may contain a groove for holding back pipe from pipe tub 400.Kickout arm 360 is secured to pivotal pipe arm 320 at kickout arm pivotconnection 312 located at the top of pivotal pipe arm 320. Pipe P hasrolled into pipe reception grooves 378 located in pipe clamp mechanisms370A and 370B where pipe clamp sets 387A, 389A and 387B, 389B will pivotabout pivotal pipe clamp arms 394A and 394B to engage pipe P.

FIG. 23A is an end perspective view of a pipe feeding mechanism inaccord with one possible embodiment of the invention. In thisembodiment, pipe tub 400 comprises a rack or support, at least a portionof which is sloped downward towards catwalk segment 311 which urges pipetowards pipe feed receptacle 424. Pipe feed receptacle 424 is movablymounted to support arms 434 for transporting pipe between pipe tub 400and catwalk segment 311. Accordingly, in one embodiment, pipe receptacle424 lifts pipe one at a time out of pipe tub 400 onto catwalk 311 and/orcatwalk moving elements 314. As used herein pipe tube 400 may comprise avolume in which multiple layers of pipe may be conveniently carried ormay simply be a pipe rack with a single layer of pipe.

FIG. 23B is another end perspective view of a pipe feeding mechanism 422in accord with one possible embodiment of the present invention. Pipefeed mechanism 422 comprises support arms 434 which, if desired, may befastened to catwalk segment 311. In one possible embodiment, pipe feedreceptacle may comprise a wall, rods, brace 425 at edge 427 of pipe feedreceptacle adjacent the incoming pipe that contains the remaining pipeon the rack when pipe feed receptacle 424 moves, in this embodiment,upwardly. Thus, the wall or rods act as a gate. Once pipe receptacle 424is lowered, then another pipe drops into pipe receptacle 424. In thisembodiment, pipe feed receptacle 424 is slidingly mounted to supportarms 434 for movement between pipe tub 400 and catwalk segment 311. Oncepipe P is moved towards catwalk segment 311, catwalk moving elements 314urge pipe P towards pipe arm 320 with kickout arm 360. Pipe feedreceptacle 424 could also be pivotally mounted to urge pipe out of pipetub 400. In another embodiment, the tub or rack of pipes may be higherthan the surface of catwalk 311 and the catwalk moving elements act asthe pipe feed to control the flow of pipe from the pipe tub or rack 400of pipe. Accordingly, the pipe feed may or may not be mounted withinpipe tube 400.

In yet another embodiment, as shown in FIG. 23C pipe tub 400 maycomprise means for moving pipe from the bottom to the top of the pipetub 400, such as a hydraulic floor or a spring loaded floor. In oneembodiment, pipe tub 400 may also contain pipe gate 426 at an upper edgeof pipe tub 400 for efficiently moving pipe from pipe tub 400 to pipefeed receptacle 424.

FIG. 23C is a cross sectional view of another possible embodiment of apipe feeding mechanism 422 with the pipes present. The embodiment ofpipe tub 400 shown in FIG. 23C may also be utilized for receiving pipeas the pipe is removed from the well in conjunction with pipe ejectionmechanisms and/or catwalk pipe moving elements discussed hereinbefore.As discussed hereinbefore, pipe tub 400 contains sloped bottom 428 andoptional pipe rungs 432 for controlling movement of pipes towards pipegate 426. The downward sloped angle of pipe rungs 432 and theirplacement inside pipe tub cavity 420 continually move pipe as pipe gate426 opens to allow pipe P to be received by pipe feed receptacle 424.Pipe feed receptacle 424 lifts pipe P to an upper position adjacent asurface of catwalk segment 311 for movement unto kickout arm 360.Various types of lifting mechanisms may be utilized for pipe feedreceptacle including hydraulic, electric, or the like. Pipe gate 426controls movement of pipe onto pipe feed receptacle 424 which issupported by vertical support member 430 and support base 440 to preventmovement during operation.

FIG. 23D is a cross sectional view of a pipe feeding mechanism 422 withthe pipes removed in accord with one possible embodiment of the presentinvention. Pipe feed mechanism 422 is positioned between pipe tub 400and catwalk segment 311. Pipe tub 400 contains pipe gate 426 at a lowerend of pipe tub 400 facing catwalk segment 311. Pipe rungs 432 may beutilized in connection with sloped bottom 428 within pipe tub 400 forcontrolling the movement of pipe P towards pipe gate 426. As discussedhereinbefore, pipe feed receptacle 424 is stabilized by vertical supportmember 430 and support base 440 while in this position. Pivotal rungsmay be removable or pivotal to open for filling the pipe tub morequickly.

FIG. 23E is a cross sectional view of a pipe feeding mechanism 422 inaccord with one possible embodiment of the present invention. In thisembodiment, pipe rungs 432 are omitted so that pipe tub cavity 420 onlycontains sloped bottom 428 and pipe gate 426. This arrangement allows ahigher volume of pipe to be stored in pipe tub 400 for drillingoperations. Sloped bottom 428 will urge pipe towards pipe gate 426 whichremotely opens and closes to allow pipe P to be received by pipe feedreceptacle 424. After pipe P has cleared pipe gate 426, it will behoisted along vertical support member 430 via pipe feed receptacle 424until it reaches catwalk segment 311. Once at catwalk segment 311, pipeP will be further urged to pipe arm 320 by catwalk moving elements 314(See FIG. 23B). In one embodiment, the pipe feeding mechanism of FIG.23E may be utilized with the pipe tub 400 of FIG. 23C. When removingpipe from the well, the pipe may be positioned onto the rungs by catwalkmoving elements and/or pipe ejection elements discussed hereinbefore.

During operation for insertion of pipes into the wellbore, pipes aremoved from pipe tubs 400 to the catwalk (if desired by automaticoperation) and in one embodiment catwalk pipe moving elements 314 areactivated to urge the pipes into pipe grooves 378 past retracted pipeclamps 387A, 389A and/or 387B, 389B. Once the pipe is in the grooves,then the pipe clamps are pivoted upwardly 387A, 389A and/or 387A, 389Ato clamp the pipes. During this time, the length and other factors ofthe pipe is sensed or read by RFID tags. Pivotal pipe arm 320 is thenrotated upwardly to the desired position (which may be determined bysensors and/or an upper mast fixture 315. Kickout arm 360 pivotsoutwardly to orient the pipe vertically.

Top drive 150 is lowered using drawworks 620 to lower traveling blockassembly 153, and top drive shaft 165 is rotated to threadably connectwith the upper pipe connector. The pipe is then lowered utilizingtraveling block assembly 153 and top drive 150 so that the lowerconnection of the pipe is connected to the uppermost connection of thepipe string already in the wellbore and the pipe may be rotated topartially make up the connection. The pipe tongs 170 are moved aroundthe pipe connection to torque the pipe with the desired torque and thetorque sensor measures the make-up torque curve to verify the connectionis made correctly. The pipe tongs are moved out of the way. The slipsare disengaged and the pipe string is lowered so that the pipe upperconnection is adjacent the rig floor and the slips are applied again tohold the pipe string. The pipe tongs may be brought back in for breakingthe connection of this pipe and may utilize reverse rotation of the topdrive to undo the connection. Using drawworks 620 to raise travelingblock assembly 153, top drive 150 is moved back toward the mast top inreadiness for the next pipe.

To remove pipe from the well bore, the top drive is raised so that thelower connection of the pipe for removal is available to be broken bypipe tongs. Once broken, the top drive may be used to undo theconnection the remainder of the way. The pipe is then raised, kickoutarm 360 is pivoted outwardly, and clamps 370A and 370B clamp the pipe.The connection to the top drive is then broken by rotation of the topdrive shaft 165, whereupon the top drive is moved out of the way.Kickout arm 360 is then pivoted back to be adjacent pivotal pipe arm320. Pivotal pipe arm 320 is lowered. Clamps 370A and 370B are releasedand retracted. Either the eject arms 374A or 374B are activateddepending on which side the pipe tube is located. Accordingly, a singleoperator can run pipe into the well, perform services, and remove pipefrom the well. Other personnel at the well site may be utilized forother functions such as cleaning pipe threads, removing threadprotectors, moving pipe onto pipe tubs, which may also simply compriseracks, checking mud measurements, checking engines, and the like as iswell known.

For alignment purposes of the present application, a wellhead, BOP,snubber stack, pressure control equipment or other equipment with thewell bore going through is considered equivalent because this equipmentis aligned with the path of the top drive.

FIG. 24A depicts a perspective view of an embodiment of a grippingapparatus 1000 engageable with a top drive, such that pipe segments canbe gripped by the apparatus 1000 to eliminate the need to thread eachindividual segment to the top drive itself. FIG. 24B depicts adiagrammatic side view of the apparatus 1000.

The apparatus 1000 is shown having an upper connector 1002 (e.g., athreaded connection) usable for engagement with the top drive, thoughother means of engagement can also be used (e.g., bolts or otherfasteners, welding, a force or interference fit). Alternatively, thegripping apparatus 1000 could be formed integrally or otherwise fixedlyattached to a top drive or similar drive mechanism.

The apparatus 1000 is shown having an upper member 1004 engaged to theconnector 1002, and a lower member 1006, engaged to the upper member1004 via a plurality of spacing members 1008. While FIGS. 24A and 24Bdepict the upper and lower members 1004, 1006 as generally circular,disc-shaped members, separated by generally elongate spacing members1008, it should be understood that the depicted configuration of thebody of the apparatus 1000 is an exemplary embodiment, and that anyshape and/or dimensions of the described parts can be used. The lowermember 1006 is shown having a bore 1010 therein, through which pipesegments can pass.

During operation, the apparatus 1000 can be threaded and/or otherwiseengaged with the top drive, then after positioning of a pipe segmentbeneath the top drive and apparatus 1000, e.g., using a pipe handlingsystem, the apparatus 1000 can be lowered by lowering the top drive. Andend of the pipe segment thereby passes through the bore 1010, such thatslips or similar gripping members disposed on the lower member 1006 canbe actuated (e.g., through use of hydraulic cylinders or similar means)to grip and engage the pipe segment. Continued vertical movement of thetop drive along the mast thereby moves the apparatus 1000, and the pipesegment, due to the engagement of the gripping members thereto.Likewise, rotational movement of the top drive (e.g., to make or unmakea threaded connection in a pipe string) causes rotation of the apparatus1000, and thus, rotation of the gripped pipe segment. The apparatus 1000is thereby usable as an extension of the top drive, such that pipesegments need not be threaded to the top drive itself, but can insteadbe efficiently gripped and manipulated using the apparatus 1000.

Other types of attachments for engagement with a top drive or otherdrive system, and/or for engaging and/or guiding a tubular joint arealso usable. For example, FIG. 25A depicts an exploded perspective viewof an embodiment of a guide apparatus 1100 engageable with a top drivesuch that tubular joints brought into contact with the guide apparatus1100 can be moved toward a position suitable for engagement with the topdrive (e.g., in axial alignment therewith). FIG. 25B depicts adiagrammatic side view of the guide apparatus 1100.

Specifically, the guide apparatus 1100 is shown having an upper member1102 that includes a connector (e.g., interior threads) configured toengage a top drive and/or other type of drive mechanism, though othermeans of engagement can also be used (e.g., bolts or other fasteners,welding, a force or interference fit). Alternatively, the guideapparatus 1100 could be formed integrally or otherwise fixedly attachedto a top drive or similar drive mechanism.

The upper member 1102 is shown engaged to the remainder of the guideapparatus 1100 via insertion through a central body 1106 having aninternal bore, such that a threaded lower portion 1104 of the uppermember 1102 protrudes beyond the lower end of the central body 1106. Acollar-type engagement, shown having two pieces 1108A, 1108B, connectedvia bolts 1110, nuts 1111, and washers 1113, can be used to secure theupper member 1102 to the remainder of the apparatus 1100, though itshould be understood that the depicted configuration is exemplary, andthat any manner of removable or non-removable engagement can be used, orthat the upper member 1102 could be formed as an integral portion of theguide apparatus 1100.

A lower member 1112 is shown below the upper member 1102, the lowermember 1112 having a generally frustroconical shape with a bore 1114extending therethrough. The shape of the lower member 1112 defines asloped and/or angled interior surface 1116. A plurality of spacingmembers 1118 are shown extending between the lower member 1112 and thecentral body 1106, thus providing a distance between the lower member1112 and the upper member 1102 and/or a top drive connected thereto.While FIGS. 25A and 25B depict the upper member 1102 and central body1106 as generally tubular and/or cylindrical structures, it should beunderstood that any shape and/or configuration could be used. Similarly,while the lower member 1112 is shown as a generally frustroconicalmember, other shapes (e.g., pyramid, partially spherical, and/or curvedshapes) could be used to present an angled and/or curved surface in thedirection of a tubular.

During operation, the guide apparatus 1100 can be threaded and/orotherwise engaged with the top drive, then after positioning of atubular joint beneath the top drive and the guide apparatus 1100 (e.g.,using a pipe handling system), the guide apparatus 1100 can be loweredby lowering the top drive. After the end of the tubular joint passesthrough the lower end of the bore 1114, the end of the tubular jointcontacts the angled interior surface 1116. Continued movement of theguide apparatus 1100 causes the tubular to move along the angledinterior surface 1116 until the end of the tubular exits the upper endof the bore 1114, where contact between the tubular and the upperportion off the lower member 1112, and/or between the tubular and thespacing members 1118 prevents further lateral movement of the tubularrelative to the guide apparatus 1100.

The end of the tubular joint can then be connected (e.g., threaded) tothe lower portion 1104 of the upper member 1102. Continued verticalmovement of the top drive along the mast thereby moves the guideapparatus 1100, and the tubular joint, due to the engagement between thejoint and the guide apparatus 1100. Likewise, rotational movement of thetop drive (e.g., to make or unmake a threaded connection in a pipestring) causes rotation of the guide apparatus 1100, and thus, rotationof the engaged tubular joint. The guide apparatus 1100 is thereby usableas an extension of the top drive, such that tubular joints need not bethreaded to the top drive itself, where misalignment can occur, but caninstead be presented in a misaligned position, contacted against theangled interior surface 1116, and moved into alignment for engagementwith the apparatus 1100. In alternate embodiments, the upper member 1102and lower portion 1104 thereof could be omitted, and a tubular jointcould be engaged with a portion of the top drive directly.

FIG. 26 is a top view of a roller and a support rail in accord with onepossible embodiment of the present invention. Roller 158 is one ofseveral rollers connected to both guide frames 152A and 152B (See FIGS.19, 19B, and 19C-C). Roller 158 is connected to guide frame 152 atroller axle 159 allowing roller 158 to spin freely around roller axle159. Support rail 176 is sized to mate with groove 173 of roller 178 tofacilitate movement of top drive 150 along support rail 176. In anotherembodiment, support rail 176 could contain groove 173 whereby roller 158is sized to engage groove 173 to facilitate movement of top drive 150.In this way, rollers 158 may be utilized to prevent rotation of the topdrive and to reduce back and forth movement as may occur in prior artsystems.

It will be understood that grooves could be provided in the guide framewhereby the rollers fit in the groove of the guide frame rather than thegroove being formed in the rollers. The grooves may be of any typeincluding straight line grooves where the grove sides may be angled orperpendicular with respect to the axis of rotation of the rollers. Aswell, the grooves may be curved. The grooves may also have combinationof angled and perpendicular lines or any variation thereof. Matingsurfaces in the opposing component, either the guides or the rollers areutilized. There may be some variation in size to reduce friction, e.g.,the groove may have a bottom width of two inches and the inserted membermay have a maximum width of 1 and three-quarters inches and so forth. Asdiscussed above, the grooves may be V-shaped or partially V-shaped.

Turning to FIGS. 27A and 27B, a top view of a crown block assembly 193in accord with one possible embodiment of the present invention. Crownblock assembly 193 has cluster of sheaves located on top of mastassembly 100. Sheaves 193A, 193B, 193C, 193D have an axis of rotation Xupon which the sheave cluster 193A, 193B, 193C, 193D rotates. Travelingsheave block assembly 153 has sheaves 146A, 146B, 146C, 146D which arefastened to said guide frame 152 of top drive fixture 150 (see FIG. 19).Traveling sheave block assembly 153 has axis of rotation Y, which isoffset in relation to axis of rotation X upon which sheave cluster 193A,193B, 193C, 193D rotates. In one embodiment, the offset is less thanninety degrees. In another embodiment, the offset is less than fortyfive degrees. In another embodiment, the offset is less than twenty fivedegrees. It will be understood that these ranges would also apply if anymultiple of ninety degrees were added to these ranges, e.g., betweenninety and one-hundred eighty degrees. This orientation improves theability of sheave cluster 193A, 193B, 193C, 193D and traveling sheaveblock assembly 153 to reeve a drilling line. When the traveling sheavesmove closely to the crown sheaves, the offset aids in providing asmoother transition from one set of sheaves to the other in that sharpbends of the drilling line are avoided.

Generally, sheave wheels have a minimum diameter with respect to thetype of drilling line to limit the amount of bending of the drillingline. Generally, the minimum sheave diameter will be between fifteentimes and thirty time the diameter of the drilling line. However, thisrange may vary. Accordingly, in some embodiments, the ratio of sheavewheel diameter to drilling line diameter may be less than twenty.

Turning to FIGS. 28A and 28B, one possible embodiment of long lateralcompletion system 10 is depicted. A well site with first wellhead 12 andsecond wellhead 14 is shown. As discussed hereinbefore, long lateralcompletion system 10 can work well with wellheads in close proximitywith each other on a well site, which can be less than a 10 footdistance between first wellhead 12 and second wellhead 14. Pipe armassembly 300 occupies a rear portion of skid 16 while rig floor 102 ispositioned at a front end of skid 16 closest to second wellhead 14. Inanother embodiment, rig floor 102 and pipe arm assembly 300 are operablewithout skid 16. Skid 16 is positioned so that rig platform 102 isdirectly above second wellhead 14. Rig floor 102 may or may not be partof skid 16.

FIG. 28B depicts long lateral completion system 10 in accord with onepossible embodiment of the present invention. Rig carrier 600 is shownwith mast assembly 100 in an upright position. Mast assembly 100 extendspast a rear portion of rig carrier 600 so that top drive unit mountedwithin mast assembly 100 is positioned directly above first wellhead 12for drilling operations, as discussed hereinbefore. In otherembodiments, sensors such as laser sights or guides mounted to the rearof rig carrier 600, and the like may be utilized, e.g., mounted toand/or guided to the well head, to locate and orient the axis of mastassembly 100 precisely with respect to the wellbore of first wellhead12.

Rig floor 102 is shown positioned above second wellhead 14 providingoperators access to mast assembly 100 when conducting drillingoperations on first wellhead 12. System 10 is configured so that pivotalpipe arm 320 of pipe handling system 300 can move pipe to and away frommast assembly 100 without contacting rig floor 102 during operation.Pivotal pipe arm 320 uses control arm 315 to pivot about pipe armpivotal connection 313 creating an angle which avoids rig floor 102.

In another embodiment of the present invention, pivotal pipe arm 320 maycontain kickout arm 360. In this embodiment, kickout arm 360 remainsgenerally parallel to pivotal pipe arm 30 except when pivotal pipe arm360 is moved into the upright position shown in FIG. 7, FIG. 8, and FIG.9. Upon reaching the upright position, kickout arm 360 is pivoted usingthe hydraulic actuators 362, which cause kickout arm 360 to pivot awayfrom pipe arm 320 about kickout arm pivot connection 312 (See FIG. 16B).This preferred configuration of long lateral completion system 10 allowsdrilling operations on multiple wells in close proximity, which can beless than 10 feet apart in certain embodiments.

While certain exemplary embodiments have been described in details andshown in the accompanying drawings, it is to be understood that suchembodiments are merely illustrative of and not devised without departingfrom the basic scope thereof, which is determined by the claims thatfollow. Moreover, it will be appreciated that numerous inventions aredisclosed herein which are taught in various embodiments herein and thatthe inventions may also be utilized within other types of equipment,systems, methods, and machines so that the invention is not intended tobe limited to the specifically disclosed embodiments.

What is claimed is:
 1. An apparatus comprising: a. a carrier; b. a mastpivotally mounted on said carrier for rotation upward to an erectdrilling position, said mast comprising: i. front vertical supportmembers and rear vertical support members; and ii. a mast top supportedatop said front and rear vertical support members; and c. a drawworksmounted on said carrier to said rear of an erect mast, said drawworkshaving a drum with a drum rotation axis perpendicular to a drilling axisfor winding and unwinding a drilling line on said drum; d. a crown blockassembly mounted in a mast top for engaging said drilling line, whereinsaid crown block assembly comprises: i. a cluster of front sheavesmounted at a front of said mast top facing said drilling axis, saidcluster of front sheaves comprising a first outermost sheave and asecond outermost sheaves and at least one inboard sheave, all aligned onan axis in a plane perpendicular to said drilling axis and having apredetermined distance between grooves of adjacent front sheaves of thecluster of front sheaves; ii. a fast line sheave mounted on saiddrawworks side of said mast top, behind a first outermost front sheaveand on an axis substantially parallel to said front sheave axis, forreeving said drilling line to said first outermost front sheave; andiii. a deadline sheave mounted on said drawworks side of said mast top,behind a second outermost front sheave and on an axis substantiallyparallel to said front sheave axis, for reeving said drilling line fromsaid second outermost front sheave to an anchorage; and e. a travelingblock assembly hung by said drilling line from said cluster of frontsheaves of said crown block assembly, comprising: i. a frame; a clusterof traveling block sheaves comprising at least a first travelling blocksheave, a first outermost traveling block sheave and a second outermosttraveling block sheave, wherein said cluster of traveling block sheavesis supported in said frame and is one less in number than the cluster offront sheaves in said crown block assembly,
 1. said cluster of travelingblock sheaves having a predetermined distance between grooves ofadjacent traveling block sheaves and rotating on a common horizontalaxis in a plane perpendicular to said drilling axis, and
 2. saidtraveling sheave axis being angled in said latter plane relative to saidaxis of said cluster of front sheaves such that said drilling linereeves downwardly from said groove in a first front sheave parallel tosaid drilling axis to engage said groove in said at least firsttraveling block sheave and reeves upwardly from said groove in saidfirst traveling block sheave toward said second front sheave nextadjacent said first front sheave at an up-going drilling line angle tosaid drilling axis effective according to said distance between saidgrooves of said first and second front sheaves to move said drillingline laterally relative to said front sheave axis and engage said grooveof said second front sheave, each traveling block sheave of said clusterof traveling block sheaves receiving said drilling line parallel to saiddrilling axis and reeving said drilling line to each following frontsheave at said up-going angle, and iii. said first outermost travelingblock sheave receiving said drilling line, reeved downward from saidfirst outermost front sheave of said crown block assembly parallel tosaid drilling axis, reeves said drilling line at said up-going angle toa next adjacent inboard front sheave, a latter inboard front sheavereeves said drilling line downward to a traveling block sheave nextadjacent said first outermost traveling block sheave parallel to saiddrilling axis, said traveling block sheave next adjacent reeves saiddrilling line at said up-going angle to a front sheave next adjacent tosaid front sheave next adjacent to said first outermost front sheave,and so forth, for each successive traveling block sheave, until saidsecond outermost traveling block sheave reeves said drilling line atsaid up-going angle to said second outermost front sheave, wherein saidsecond outermost front sheave reeves said drilling line to said deadlinesheave, and wherein said deadline sheave reeves said drilling line tosaid anchorage.
 2. The apparatus of claim 1, further comprising guiderails connected to said front vertical support members and parallel to adrilling axis in front of and between said guide rails.
 3. The apparatusof claim further comprising a guide frame moveable along said guiderails on rollers engaging said guide rails.
 4. The apparatus of claim 3,wherein said frame supporting said traveling block sheaves includes adownwardly projecting extension laterally outwardly attached to saidguide frame.
 5. The apparatus of claim 4, wherein at least two of saiddownwardly projecting extensions are adapted to receive a top drivebetween them for fastening to them.
 6. The apparatus of claim 5, inwhich said frame further comprises: a. front, rear and side plates, saidside plates including said downwardly projecting extensions; b. a crossmember spanning said side plates above said cluster of traveling blocksheaves sufficiently within parallel planes tangent to peripheries offlanges of said cluster of traveling block sheaves such that saiddrilling line does not contact said cross member, said cross membermounting a plurality of rigid spaced apart hangers each in a planeperpendicular to said front sheave axis; and c. an axle for eachtraveling block sheave, supported between adjacent pairs of said hangersparallel to said plane of said front sheave axis, and about which saidtraveling block sheave rotates in an angled traveling sheave axis. 7.The apparatus of claim 2, wherein said up-going angle is about 12degrees.
 8. The apparatus of claim 1, wherein said up-going angle is notmore than about 15 degrees.
 9. The apparatus of claim 1, wherein apredetermined distances between grooves of said front sheaves is equalfrom sheave to sheave.
 10. The apparatus of claim 1, wherein saidcluster of front sheaves comprise more than one inboard sheave.
 11. Theapparatus of claim 10, wherein said predetermined distance between atleast one pair of inboard front sheaves is different than said distanceseparating at least one sheave from said first outermost front sheaveand said second outermost front sheave from a next adjacent inboardfront sheave.
 12. A method of moving a top drive vertically along adrilling axis, comprising: a. providing a guide frame moveable onrollers engaging guide rails parallel to said drilling axis in front ofand between said guide rails, said guide rails being connected to frontvertical support members of an erect mast; b. providing a travelingblock assembly hung by a drilling line from a crown block assembly on amast top of said mast, said traveling block assembly comprising a framesupporting a cluster of traveling block sheaves, said frame includingdownwardly projecting extensions laterally outwardly attached to saidguide frame, said downwardly projecting extensions mounting said topdrive aligned with said drilling axis between said downwardly projectingextensions; c. providing a drawworks to a rear of said erect mast, saiddrawworks having a drum with a drum rotation axis perpendicular to saiddrilling axis for winding and unwinding a drilling line on said drum; d.providing said crown block assembly mounted in said mast top forengaging said drilling line, wherein said crown block assemblycomprises: i. a cluster of front sheaves mounted at a front of said masttop facing said drilling axis, said cluster of front sheaves comprisinga first outermost front sheave, a second outermost front sheaves and atleast one inboard sheave, all aligned on an axis in a planeperpendicular to said drilling axis and having a predetermined distancebetween grooves of adjacent front sheaves of said cluster of frontsheaves; ii. a fast line sheave mounted on a drawworks side of said masttop, behind a first outermost front sheave, and on an axis substantiallyparallel to said front sheaves axis, for reeving said drilling line tosaid first outermost front sheave; and iii. a deadline sheave mounted onsaid drawworks side of said mast top, behind a second outermost frontsheave, and on an axis substantially parallel to said front sheavesaxis, for reeving said drilling line from said second outermost frontsheave to an anchorage, wherein said cluster of traveling block sheavesnumbers one less than said cluster of said front sheaves in said crownblock assembly and includes at least a first traveling block sheave anda second traveling block sheaves, at least one of said first travelingblock sheave and said second traveling block sheaves having apredetermined distance between grooves of adjacent traveling sheaves androtating on a common horizontal axis in a plane perpendicular to saiddrilling axis, wherein said traveling sheaves axis is angled in saidlatter plane relative to said axis of said front sheaves such that saiddrilling line reeves downwardly from a groove in a first front sheaveparallel to said drilling axis to engage a groove in a first travelingblock sheave and reeves upwardly from said groove in said firsttraveling block sheave toward said second front sheave next adjacentsaid first front sheave at an up-going drilling line angle to saiddrilling axis effective according to said distance between said groovesof said first and second front sheaves to move said drilling linelaterally relative to said front sheave axis and engage said groove ofsaid second front sheave, each said traveling block sheave of saidcluster of traveling block sheaves receiving said drilling line parallelto said drilling axis and reeving said drilling line to each followingfront sheave at said up-going angle, wherein said first outermosttraveling block sheave receiving said drilling line, reeved downwardfrom said first outermost front sheave of said crown block assemblyparallel to said drilling axis, reeves said drilling line at saidup-going angle to a next adjacent inboard front sheave, a latter inboardfront sheave reeves said drilling line downward to said traveling blocksheave next adjacent said first outermost traveling block sheaveparallel to said drilling axis, wherein said traveling block sheave nextadjacent reeves said drilling line at a-said up-going angle to a frontsheave next adjacent to said front sheave next adjacent to said firstoutermost front sheave, and so forth, for each successive travelingblock sheave, until said second outermost traveling block sheave reevessaid drilling line at said up-going angle to said second outermost frontsheave, wherein said second outermost front sheave reeves said drillingline to said deadline sheave, and wherein said deadline sheave reevessaid drilling line to said anchorage; e. providing motive power to saiddrawworks to wind said drilling line on said drawworks drum to raisesaid traveling block assembly and said frame mounting said top drive andsaid guide frame, guiding said top drive along said drilling axis byrolling said guide frame on said rollers along said guide rails; and f.providing motive power to said drawworks to unwind said drilling line onsaid drawworks drum to lower said traveling block assembly and saidframe mounting said top drive and said guide frame, guiding said topdrive along said drilling axis by rolling said guide frame along saidguide rails.
 13. The method of claim 12, further comprising guide railsconnected to said front vertical support members and parallel to adrilling axis in front of and between said guide rails.
 14. The methodof claim 13, further comprising a guide frame moveable along said guiderails on rollers engaging said guide rails.
 15. The method of claim 14,wherein said frame supporting said traveling block sheaves includes adownwardly projecting extension laterally outwardly attached to saidguide frame.
 16. The method of claim 15, wherein at least two of saiddownwardly projecting extensions are adapted to receive a top drivebetween them for fastening to them.
 17. The method of claim 16, whereinsaid frame further comprises: a. front, rear and side plates, said sideplates including said downwardly projecting extension; b. a cross memberspanning said side plates above said cluster of traveling block sheavessufficiently within parallel planes tangent to peripheries of flanges ofsaid cluster of traveling block sheaves such that said drilling linedoes not contact said cross member, said cross member mounting aplurality of rigid spaced apart hangers each in a plane perpendicular tosaid front sheave axis; and c. an axle for each traveling block sheave,supported between adjacent pairs of said hangers parallel to said planeof said front sheave axis, and about which said traveling block sheaverotates in an angled traveling sheave axis.
 18. The method of claim 13,wherein said up-going angle is about 12 degrees.
 19. The method of claim12, wherein said up-going angle is not more than about 15 degrees. 20.The method of claim 12, wherein said predetermined distances betweengrooves of said adjacent front sheaves is equal from sheave to sheave.